Filter Media Packs, Methods of Making, and Ultrasonic Cutting or Welding

ABSTRACT

The present disclosure is directed toward assembly of pleat packs using a welder and an anvil that can push adjacent pleat panels together along a crease. Other aspects are directed to welding pocket pleats and welded pocket pleats formed thereby that are suitable for filter fluid and ultrasonically cutting and sealing seams into filter media using a welding assembly such as an ultrasonic sonotrode and an anvil.

CROSS-REFERENCE TO RELATED PATENT APPLICATIONS

This patent application is a continuation-in-part of U.S. patentapplication Ser. No. 15/896,589 filed Feb. 14, 2018, which is acontinuation of U.S. Patent Application No. PCT/US2016/047283, filedAug. 17, 2016; this patent application also claims the benefit of U.S.Provisional Patent Application No. 62/206,100, filed Aug. 17, 2015; andU.S. Provisional Patent Application No. 62/243,740, filed Oct. 20, 2015.This application is also a continuation of U.S. Patent Application No.PCT/US2018/017952, filed Feb. 13, 2018; this patent application alsoclaims the benefit of U.S. Provisional Patent Application No. 62/459,990filed, Feb. 16, 2017. The entire teachings and disclosure of all of theprovisional, PCT and non-provisional patent applications referencedabove are incorporated herein by reference thereto.

FIELD OF THE INVENTION

This invention generally relates to filters, and more particularlyrelates to methods and machinery for forming features such asembossments (that may define grooves), creases, graphics, or otherfeatures into filter media packs and such filter media packs formedthereby.

BACKGROUND OF THE INVENTION

A variety of filter packs are known in the prior art, for example U.S.Pat. No. 6,780,217 to Palmer; U.S. Pat. No. 7,122,068 to Tate et al.;U.S. Pub. No. 2006/0151383 to Choi; U.S. Pat. No. 4,268,290 toBarrington. Each of the aforementioned patents and publicationsgenerally relate to pleated filter media elements.

There is also other filter media packs such as fluted media packsdescribed and shown for example in U.S. Pub. No. 2014/0260139 entitledRectangular Stacked Fluted Filter Cartridge to Merritt; and U.S. Pat.No. 7,318,851 entitled Filter Element to Brown et al.

Generally, the process for processing the filter media to be used insuch filter media packs employed by the above examples requires the useof rolls that have projecting features that rotate around a central axisin order to form embossments or other features into the filter mediapack such as shown for example in Choi, U.S. Pub. No. 2006/0151383entitled Pleated Corrugated Media and Method of Making. The advantage ofthe roll forming process is the ability for continuous processing inthat the rolls rotate and operate continuously on a continuous filtermedia sheet that is unwound from a filter media roll in a typicalprocess.

Various aspects of the present invention are directed towardsimprovements in the methods of making such features on media packs,improved media pack structures, and/or improved pleated embossed mediapacks as will be understood from the disclosure below.

BRIEF SUMMARY OF THE INVENTION

Various aspects are provided that may be used alone or in combinationwith each other in various embodiments such as those aspects below inthis summary section.

In one aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet. The method comprisingpleating the filter media sheet to provide a plurality of pleat panelsand welding a plurality of seams into a plurality of adjacent pairs ofthe pleat panels to form a plurality of pocket pleats.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet including advancing thefilter media sheet along a travel path and said pleating comprisingcreasing the filter media sheet at spaced intervals in order to form thepleat panels with a plurality of pleat tips in the pleated filter mediapack by extending the creasing in a direction that extendsperpendicularly to the travel path.

In another aspect, an embodiment provides a the method for forming apleated filter media pack with a filter media sheet including after thepleating and welding, overlaying the pocket pleats upon each other toform the pleated filter media pack.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where the pleated filtermedia pack includes a plurality of upstream pleat tips at an upstreamface and a plurality of downstream pleat tips at a downstream face. Thepleat panels extend between the upstream pleat tips and the downstreampleat tips. Each of the pleat panels extend transversely between firstand second opposed side edges of the pleat panels. Welding is performedthat integrally bonds the first and second opposed side edges at spacedapart locations.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet including bonding togetherthe adjacent pleat panels at locations between the first and secondopposed side edges.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where welding is conductedon at least one of the upstream pleat tips and the downstream pleat tipsat spaced apart locations along at least one of the upstream pleat tipsand the downstream pleat tips.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where the filter media sheetcomprises at least 10% polymer fibers by weight to facilitate welding.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where the polymer fiberscomprise at least one of a polypropylene and polyester.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet including welding with alinearly reciprocating press. The linearly reciprocating press includesan anvil and a weld tool. The method further includes supplying thermalenergy between the anvil and the weld tool from a thermal energy deviceto facilitate the welding.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet by ultrasonically weldingwith an ultrasonic press that forms the pocket pleats therebetween. Theultrasonic press includes an anvil and a sonotrode, with a ribprojection being provided along at least one of the anvil and thesonotrode.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where the rib projection isprovided on the anvil and projects toward the sonotrode.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where the rib projection isprovided by a removable tool arranged on a plate of at least one of theanvil and the sonotrode. The method further includes removing theremovable tool and rearranging the removable tool or replacing theremovable tool with a second removable tool, and using the rearrangedremovable tool or the second removable tool to form differentconfigurations of filter media packs.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet including linearlyreciprocating the anvil and the sonotrode relative to each othertogether and apart to ultrasonically weld seams in the filter mediasheet.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet that includes carrying theanvil on a first carriage mounted on a first linear slide and carryingthe sonotrode on a second carriage mounted on a second linear slide. Themethod further includes linearly sliding each of the anvil and sonotrodeindependently, together and apart along a Z axis, to facilitate thewelding of the seams and releasing of the pocket pleats to allowoverlaying of the pocket pleats upon each other to form the pleatedfilter media pack.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where linearly reciprocatingof the anvil and sonotrode is conducted in a Z-axis. The method furtherincludes moving a location of the rib projection along at least one axisperpendicular to the Z axis during formation of the pleated filter mediapack to form the pleated filter media pack in an irregular shape ofother than a rectangular cuboid.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where the rib projectionincludes first and second parallel linear projection elements in spacedapart relation. The method further includes engaging the first andsecond opposed side edges of the pocket pleats with the first and secondparallel linear projection elements.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet including a linear slideassembly on which the first and second parallel linear projectionelements are mounted. The method further includes adjusting a spacingbetween the first and second parallel linear projection elements bymoving at least one of the first and second linear projections along thelinear slide assembly during the formation of the pleated filter mediapack to form the pleated filter media pack in an irregular shape ofother than a rectangular cuboid.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet including a knife projectionprovided along at least one of the anvil and the sonotrode. The knifeprojection is thinner than the rib projection and cuts through theadjacent pairs of pleat panels.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet where the knife projectionis proximate to at least a portion of the rib projection and the knifeprojection cuts at least one seam that is ultrasonically weldedsimultaneously by the rib projection.

In another aspect, an embodiment provides a method for forming a pleatedfilter media pack with a filter media sheet that includes intermittentlyand successively advancing and stopping the filter media sheet along atravel path. Then while the filter media sheet is stopped at least oneof embossing and creasing is conducted. While the filter media sheet isadvancing a leading portion is being folded along a crease.

In yet another aspect, an embodiment provides a method of forming apleated filter media pack with a filter media sheet. The method includespleating the filter media sheet to provide a plurality of pleat panels.The method further includes cutting a plurality of seam edges into aplurality of adjacent pairs of the pleat panels and bonding and sealingthe adjacent pairs of the pleat panels along the seam edges sufficientlyto prevent unfiltered fluid from passing through the seam edges in thepleated filter media pack.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes advancing thefilter media sheet along a travel path. The pleating includes creasingthe filter media sheet at a plurality of spaced intervals in order toform the pleat panels to provide a plurality of pleat tips in thepleated filter media pack by extending the creasing in a direction thatextends perpendicularly to the travel path. The method further includesultrasonically cutting seam edges in an extension extending transverselyrelative to the travel path.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes forming acutout region in the pleated filter media pack with the ultrasonicallycut seam edges to form the filter media pack in an irregular shape ofother than a rectangular cuboid.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the pleated filtermedia pack comprises a plurality of upstream pleat tips at an upstreamface and a plurality of downstream pleat tips at a downstream face. Thepleat panels extend between the upstream pleat tips and the downstreampleat tips where each of the pleat panels extend transversely betweenfirst and second opposed side edges. The method includes ultrasonicallywelding a plurality of integral bonds along the first and second opposedside edges to form a plurality of pocket pleats.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the pleated filtermedia pack comprises a plurality of upstream pleat tips at an upstreamface and a plurality of downstream pleat tips at a downstream face withthe pleat panels extending between the upstream pleat tips and thedownstream pleat tips. Each of the pleat panels extend transverselybetween first and second opposed side edges of the pleat panels. Themethod includes ultrasonically welding the adjacent pair of the pleatpanels together at locations between the first and second opposed sideedges.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where an ultrasonic presscomprises an anvil and a sonotrode. The method includes a knifeprojection and a rib projection that are provided between the anvil andthe sonotrode to facilitate ultrasonically cutting of the seam edges.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the knife projectionand correspondingly the seam edges are curved or non-linear.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the knife projectionis provided by a removable tool arranged on a support member of at leastone of the anvil and the sonotrode. The method further includes removingthe removable tool and rearranging the removable tool or replacing theremovable tool with a second removable tool. The rearranged removabletool or the second removable tool is used to form a differentconfiguration of the filter media pack.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes linearlyreciprocating the anvil and the sonotrode together and apart toultrasonically cut the seam edges.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes carrying theanvil on a first carriage mounted on a first linear slide. The methodfurther includes carrying the sonotrode on a second carriage mounted ona second linear slide and linearly sliding each of the anvil andsonotrode together and apart along a Z axis to facilitate theultrasonically cutting of the seam edges.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes moving alocation of the knife projection along at least one axis perpendicularto the Z-axis during the formation of the pleated filter media pack toform the pleated filter media pack in an irregular shape of other than arectangular cuboid.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where a rib projection isprovided adjacent the knife projection. The knife projection is thinnerthan the rib projection and proximate to the rib projection. The methodfurther includes ultrasonically cutting the seam edges whilesimultaneously ultrasonically welding the cut seam edges to form pocketpleats.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes intermittentlyand successively advancing and stopping the filter media sheet along atravel path. When the filter media sheet is stopped at least one ofembossing and creasing is conducted. While the filter media sheet isadvancing a leading portion of the filter media sheet is being foldedalong a crease.

In yet another aspect, an embodiment provides a pleated filter mediapack. The pleated filter media pack includes a filter media sheet thatis folded to include a plurality of folds that provide a plurality ofpleat panels extending between an inlet face and an outlet face of thepleated filter media pack. The folds extend between first and secondopposed side edges of the pleated filter media pack. The filter mediapack further includes an outer periphery in a surrounding relation thatextends between the inlet face and the outlet face. A welded seam isformed along the first and second opposed side edges to form pocketpleats between adjacent pairs of pleat panels. The welded seam preventsunfiltered air flow from passing through the outer periphery and betweenthe inlet and outlet faces.

In another aspect, an embodiment provides a filter media pack where thewelded seam includes a first weld seam segment along the first opposedside edge and a second weld seam segment along the second opposed sideedge. The first and second weld seams extend non-parallel relative toeach other.

In another aspect, an embodiment provides a filter media pack thatincludes a plurality of cut seam edges on a plurality of adjacent pairsof the pleat panels extending transverse to the inlet and outlet facesand transverse relative to the first and second opposed side edges. Thecut seam edges form a recess region. The adjacent pairs of the pleatpanels are integrally welded together at the cut seam edges to preventunfiltered fluid flow therethrough.

In another aspect, an embodiment provides a filter media pack where atleast one panel of each of the adjacent pairs of the pleat panels has aplurality of embossments formed therein. The embossments space the pleatpanels by between 2 millimeters and 8 millimeter and the pleat panelsextend at least 10 centimeters between the folds.

In another aspect, an embodiment provides a filter media pack where thewelded seam comprises a first weld seam segment along the first opposedside edge and a second weld seam segment along the second opposed sideedge. The first and second weld seam segments extend parallel with eachother.

In yet another aspect, an embodiment provides a pleated filter mediapack. The pleated filter media pack includes a filter media sheet thatincludes a plurality of folds that provide a plurality of pleat panelsextending between an inlet face of the pleated filter media pack and anoutlet face of the pleated filter media pack. The folds extend betweenfirst and second opposed side edges of the pleated filter media pack.The filter media pack includes an outer periphery in surroundingrelation that extends from the inlet face to the outlet face. Thepleated filter media pack further includes a plurality of cut seam edgeson a plurality of adjacent pairs of the pleat panels that extendtransverse to the inlet and outlet end faces, and transverse relative tothe first and second opposed side edges. The adjacent pairs of the pleatpanels are integrally welded together at the cut seam edges to preventunfiltered fluid flow therethrough.

In another aspect, an embodiment provides a pleated filter media packwhere the cut seam edges form a recess region defined in the pleatedfilter media pack.

In another aspect, an embodiment provides a pleated filter media packwhere the recess region is defined into one of the inlet and outletfaces.

In another aspect, an embodiment provides a pleated filter media packwhere the cut seam edges are curved.

In another aspect, an embodiment provides a pleated filter media packwhere the adjacent pairs of the pleat panels are bonded together at thefirst and second opposed side edges to provide a plurality of pocketpleats.

In another aspect, an embodiment provides a pleated filter media packwhere at least one panel of each of the adjacent pairs of the pleatpanels comprises a plurality of embossments formed therein. Theembossments space the pleat panels by between 2 millimeters and 8millimeter and the pleat panels extend at least 10 centimeters betweenthe folds.

In another aspect, an embodiment provides a pleated filter media packwhere the pleated filter media pack comprises an irregular shape ofother than a rectangular cuboid.

In yet another aspect, an embodiment provides a method of forming apleated filter media pack with a filter media sheet. The methodcomprises creasing the filter media sheet to provide a plurality ofpleat panels and arranging a crease created by the creasing between aweld tool and an anvil. The method further includes assembling anadjacent pair of the pleat panels by reciprocating the weld tool and theanvil together and apart relative to each other. The method optionallyincludes welding the adjacent pair of the pleat panels at a weldlocation while the weld tool and anvil are together.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the reciprocatingbetween the weld tool and the anvil comprises facilitating relativelinear reciprocating movement between the anvil and the weld tool alonga linear slide assembly.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that further includesdriving at least one of the weld tool and the anvil with a servomotor ora stepper motor.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where a first servomotorlinearly reciprocates the anvil and a second servomotor linearlyreciprocates the weld tool.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the weld tool is asonotrode. The method further including emitting a vibration frequencyof at least 15,000 hertz along the sonotrode to weld the pleat panels.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where one of the anvil andthe weld tool is part of a pick member and the other one of the anviland the weld tool is part of a stop member. The assembling operationincludes holding the filter media sheet with the pick member andadvancing the filter media sheet during the holding toward the stopmember. This pulls a trailing portion of the filter media sheet with thepick member and pushes a leading portion of the filter media sheet withthe pick member (the leading portion comprising the adjacent pair of thepleat panels). The assembling operation further includes folding theleading portion of the filter media sheet along the crease by drivingthe pick member and the stop member together.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes releasing theassembled adjacent pair of the pleat panels from between the weld tooland the anvil and overlaying the assembled adjacent pair of the pleatpanels onto a partly formed portion of the pleated filter media pack toform a pleated segment of the pleated filter media pack.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the releasingoperation comprises driving the stop member away from the pick member toopen a region for the assembled adjacent pair of the pleat panels.Further, the method comprises gravitationally dropping the assembledadjacent pair of the pleat panels through the region onto the partlyformed portion of the pleated filter media pack.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the anvil is part ofthe pick member. The method further includes driving the anvil and thepick member up to release the filter media sheet in a release state anddriving the anvil and the pick member down to hold the filter mediasheet in a hold state. The method also includes advancing the pickmember in the hold state, and after advancing the pick member in thehold state, releasing the filter media sheet to achieve the releasestate and then retracting the pick member to a start position.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes pushing thecrease vertically upward during the assembling to facilitate folding ofthe pleat panels.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes cutting firstand second edges into the adjacent pair of the pleat panels where thefirst and second edges are extending obliquely relative to the creasefor creating an irregular shape to the pleated filter media pack. Themethod further includes welding the first and second edges to form awelded seam.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the cutting and thewelding are conducted simultaneously while the weld tool and anvil aretogether.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where cutting is conductedseparately after creasing but before assembling.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where cutting is conductedseparately before creasing.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes welding aplurality of seams into the adjacent pairs of the pleat panels to form aplurality of pocket pleats. The pleated filter media pack comprises aplurality of upstream pleat tips at an upstream face and a plurality ofdownstream pleat tips at a downstream face with the pleat panelsextending between the upstream pleat tips and the downstream pleat tips.Each of the pleat panels extend transversely between first and secondopposed side edges of the pleat panels. Welding integrally bonds thefirst and second opposed side edges in spaced apart weld locations.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the filter media sheetcomprises at least 10% polymer fibers by weight to facilitate weldingand the polymer fibers comprise at least one of a polypropylene andpolyester.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where an ultrasonic press isused to ultrasonically weld the plurality of pocket pleats. Theultrasonic press comprises the anvil and the weld tool is a sonotrode. Arib projection is provided along at least one of the anvil and thesonotrode.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the rib projection isprovided by a removable tool arranged on a support member of at leastone the anvil and the sonotrode. The method further includes rearrangingthe removable tool or replacing the removable tool with a secondremovable tool. The rearranged removable tool or the second removabletool can be used for forming different configurations of the filtermedia pack.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet in which the method includescarrying the anvil on an anvil carriage mounted on a first linear slideand carrying the sonotrode on a sonotrode carriage mounted on a secondlinear slide. The method also includes linearly sliding each of theanvil and sonotrode together and apart independently along a Z-axis viathe anvil carriage and the sonotrode carriage, respectively, tofacilitate the welding. The pocket pleats are then released in order toallow overlaying of the pocket pleats upon each other to form thepleated filter media pack.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet where the anvil andsonotrode are reciprocated relative to each other along a Z-axis. Themethod further includes moving a location of the rib projection along atleast one axis perpendicular to the Z axis during formation of thepleated filter media pack to form the pleated filter media pack in anirregular shape of other than a rectangular cuboid.

In another aspect, an embodiment provides a method of forming a pleatedfilter media pack with a filter media sheet that includes a linear slideassembly on which first and second parallel linear projections aremounted. The method further includes adjusting spacing between the firstand second parallel linear projections by moving at least one of thefirst and second parallel linear projections along the linear slideassembly during the formation of the pleated filter media pack to formthe filter media pack in an irregular shape of other than a rectangularcuboid.

In yet another aspect, an embodiment provides an apparatus forassembling a filter media pack. The apparatus for assembling the filtermedia pack comprises a filter media supply station adapted to contain afilter media and a filter processing station downstream of the filtermedia supply station to receive the filter media. The filter processingstation comprising a media forming tool adapted to form a feature intothe filter media. The apparatus further includes an ultrasonic pressstation downstream of the filter processing station that includes ananvil and a sonotrode. A Z-axis actuator is arranged to act upon atleast one of the anvil and the sonotrode to linearly reciprocate theanvil and the sonotrode together and apart along a Z-axis.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack that includes a Z-axis linear slide assemblyoperably connected to at least one of the anvil and the sonotrode toguide the relative linear reciprocating movement between the anvil andthe sonotrode.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack where the Z-axis linear slide assembly includes alinear guide and an anvil carriage that carries the anvil. The anvilcarriage is linearly movable on the linear guide.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack that includes a sonotrode carriage slidablymounted on the linear guide. The sonotrode carriage carries thesonotrode. The apparatus further includes first and second linearactuators that act independently upon the anvil carriage and sonotrodecarriage, respectively.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack that includes a Y-axis linear slide assemblycarrying the anvil on the anvil carriage. The anvil is linearly movablein a Y-axis relative to the anvil carriage. The Y-axis is perpendicularto the Z-axis. A Y-axis actuator acts upon the anvil and is operable tomove the anvil linearly along Y-axis linear slide assembly.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack including a media support. The media supportincludes at least one of a table and a conveyor. Further provided is ananvil carriage carrying an anvil over a range of movement over the mediasupport in the Z-axis. The media support defines an opening regionbetween the anvil and the sonotrode for allowing the filter media torelease from between the sonotrode and the anvil. Further, at least oneof the anvil carriage and the anvil comprises a gripper arranged abovethe media support. The gripper is operable to hold the filter mediaduring movement along the Z-axis. A Y-axis actuator operable to move thegripper along the Y-axis.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack where the gripper is operable in a hold state topinch the filter media against the media support during movement alongthe Z-axis, and operable to release the filter media from the mediasupport in a release state. The gripper is movable between the holdstate and the release state via the Y-axis actuator.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack including an X-axis linear slide assembly carriedby the anvil carriage and carrying an anvil tool. The anvil toolincludes at least one projection including at least one of a ribprojection for welding seams in the filter media and a knife projectionfor cutting cuts into the filter media. The anvil tool faces thesonotrode, where the X-axis is perpendicular to the Z-axis.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack where the X-axis is transverse to a Y-axis.Further the Y axis may extend vertically and perpendicular to theZ-axis, with the anvil tool being movable in the Y-axis.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack in which the X-axis movement of the anvil isperpendicular to the Y-axis movement of the anvil.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack that includes at least one of a stepper motor anda servomotor acting upon the anvil tool and operable to drive the anviltool in increments along the X-axis linear slide assembly.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack where the anvil tool includes first and secondindependent tool elements. The first and second independent toolelements are separately movable along the X-axis linear slide assembly.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media pack where the sonotrode includes an ultrasonic emitterhaving an operating state emitting a high frequency movement of at least15,000 kilohertz to a sonotrode plate.

In another aspect, an embodiment provides an apparatus for assemblingthe filter media where the sonotrode plate is flat without a projectingtooling.

Other aspects, objectives and advantages of the invention will becomemore apparent from the following detailed description when taken inconjunction with the accompanying drawings.

BRIEF DESCRIPTION OF THE DRAWINGS

The accompanying drawings incorporated in and forming a part of thespecification illustrate several aspects of the present invention and,together with the description, serve to explain the principles of theinvention. In the drawings:

FIG. 1 is a partially schematic side elevation view of a pressed pleatmachine assembly and line that is creating pressed, pleated and embossedfilter media packs, with circles indicating an enlarged portion of thepress and cross-sectional and top schematic views of the embossed andscored and creased filter media sheet;

FIG. 2 is an isometric view of an upper top stamping die in the form ofan embossing plate according to an embodiment of the present inventionthat is usable in the press illustrated in FIG. 1;

FIGS. 3, 4 and 6 are bottom, front and side views of the embossing plateshown in FIG. 2;

FIG. 5 is an enlarged view of a region of FIG. 4 taken about a circle;

FIG. 7 is an isometric view of a lower bottom stamping die in the formof an embossing plate usable in the press shown in FIG. 1 in conjunctionwith the top plate shown in FIGS. 2-6;

FIGS. 8, 9, and 11 are top, front and side views of the bottom embossingplate shown in FIG. 7;

FIG. 10 is an enlarged view of FIG. 9 taken about the indicated circle;

FIG. 12 is an additional perspective illustrations of a bottom embossingplate the same or similar to that shown in FIG. 7 and used or usable inin the assembly and line of FIG. 1, but with additional score barsattached to upstream and downstream sides or ends of the embossing plateto provide a press plate assembly;

FIG. 12a is an enlarged view of FIG. 12 taken about the indicatedcircle;

FIG. 13 is a front view of the respective plate assembly shown in FIGS.12 and 7 with both upper and lower embossing plates illustrated and withupper and lower score bars attached thereto, with the plates shown inthe engaged position with the corresponding embossed features beingreceived into each other and the score features being received into eachother;

FIGS. 15, 16 and 16A are partially schematic top view andcross-sectional side view and cross-sectional end view illustrations,respectively, of a pressed media sheet formed through the press assemblyshown in FIG. 1.

FIG. 17 is an isometric view of a bottom embossing plate similar to FIG.7 and also usable in the press assembly and line of FIG. 1 but that hastapered regions at ends of the embossed groove pattern;

FIG. 18 is an end view of the embossing plate shown in FIG. 17;

FIG. 19 is an enlarged view of a portion of FIG. 17 from a front side;

FIG. 20 is an isometric view of stamping die in the form of a topembossing plate shown in isometric usable with the lower stamping dieshown in FIG. 17;

FIG. 21 is an end view of the upper embossing plate shown in FIG. 20;

FIG. 22 is an enlarged view of a region of the frontal portion of FIG.20;

FIG. 23 is another isometric view of a further embodiment of a bottomgrooving plate usable in the press of FIG. 1 but having wide and narrowV-shape to the embossed groove pattern;

FIG. 24 is an end view of the embossing plate shown in FIG. 23;

FIG. 25 is a front view of a portion of the embossing plate shown inFIG. 23 to better illustrate the wide and narrow V-shaped groove detail;

FIG. 26 is an isometric view of a top embossing plate usable with theembossing plate shown in FIG. 23 also with the widening and narrowing Vgroove feature;

FIG. 27 is an end view of the embossing plate shown in FIG. 26;

FIG. 28 is an enlarged frontal view of a portion of the front of theembossing plate shown in FIG. 26;

FIG. 29 is an isometric view of another embodiment of a bottom embossingplate having a tapering groove profile and that is usable in the pressillustrated in FIG. 1;

FIG. 30 is an end view of the embossing plate shown in FIG. 29;

FIG. 31 is an enlarged front view of a portion of the embossing plateshown in FIG. 29;

FIG. 32 is an isometric view of a top embossing plate usable with theembossing plate shown in FIG. 29, also having the tapering grooveprofile;

FIG. 33 is an end view of the embossing plate shown in FIG. 32;

FIG. 34 is an enlarged front view of a portion of the embossing plateshown in FIG. 32 to better show the tapering groove profile;

FIG. 35 is a schematic illustration of a curved embossing press plateassembly including upper and lower plates shown in a frontal andpartially schematic view according to a further embodiment of thepresent invention that is also usable in the press illustrated in FIG.1;

FIG. 36 is a perspective illustration of an air filter cartridgeaccording to an embodiment that can employ the pleated filter media packcreated according to the embodiments of FIGS. 1, 15, 16 and/or 43, orother such embodiments discussed herein;

FIG. 37 is a top view of the filter cartridges shown in FIG. 36;

FIG. 38 is a partly schematic top view of an embossed and creased filtermedia sheet according to an embodiment of the present invention that maybe made using the press of FIG. 1;

FIG. 39 is a partly schematic top view of embossed and creased filtermedia sheet for making a pleated filter media pack according to anotherembodiment that may be made using the press of FIG. 1;

FIG. 40 is a partly schematic top view of a filter media sheet includingembossments and creases for making a pleated filter media pack accordingto a further embodiment of the present invention;

FIG. 41 is a partly schematic top view of a further embodiment of anembossed increased filter media sheet that has had its edges trimmed andcut away for creating a non-cuboid shape pleated filter media pack;

FIG. 42 is a schematic side illustration of a pleated filter media packshowing that the folds or creases at one end may be pinched closertogether at one of the flow faces as compared to the other flow face toprovide a fan or tapering profile to a filter media pack from one flowface to the other flow face;

FIG. 43 is an isometric view of at least part of a pressed pleatedfilter media pack that can be made in a standard cuboid form made by thepress assembly in line of FIG. 1 according to an embodiment of thepresent invention;

FIG. 44 is an isometric view of an alternative embodiment of a pressedpleated filter media pack according to another embodiment of the presentinvention made by the press assembly in line of FIG. 1 wherein theembossed panel and non-embossed panel have differing lengths to providea non-cuboid shape;

FIGS. 45 and 46 are isometric views of two additional furtheralternative curved pressed pleated filter media packs whereby edges havebeen trimmed via a trimming knife using the trimming option device shownin FIG. 1 and wherein pairs of adjacent panels along the sides and atone of the end faces have been seamed together such as via ultrasonicwelding, and wherein dashed lines in FIG. 46 show where trimming hasoccurred;

FIGS. 47 and 48 are additional isometric views of pressed pleated filtermedia packs having non-cuboid shapes wherein the optional trimming knifein FIG. 1 has been used to trim or cut individual panels into suchshapes to form these shaped packs;

FIG. 49 is an isometric view of yet another embodiment of a pressedpleated filter media pack made by the press assembly in line of FIG. 1wherein the optional trimming device has been used to cut the panels totrapezoidal shape and wherein the sides have been seamed together toform pocket pleats;

FIGS. 50 and 51 are side and isometric views of a further embodiment ofa pressed pleated filter media pack wherein the embossed panels and thenon-embossed panels each vary in size and distance from one side toanother side to provide for a non-cuboid shape;

FIGS. 52 and 53 are another embodiment of a pressed pleated filter mediapack similar to that shown in FIGS. 50 and 51 also with varying pressedembossed and non-embossed panel lengths to provide a non-cuboid shape;

FIG. 54 is a side end view of an embossed pressed pleased filter mediapack whereby the embossments are skewed and do not run perpendicular tothe inlet and outlet flow faces and wherein each panel is embossed withgrooves having a different skew (note a first set of skewed embossmentsshowed in solid lines and a second set of embossments on a panel behindshown in dashed lines) and only two panels of the filter media packbeing shown with solid and dashed lines;

FIG. 55 is an isometric view of a further embodiment of a pressedpleated filter media pack wherein adjacent sets of panels are shiftedrelative to each other such that at least two of the sides arenon-planar;

FIG. 56 is a further embodiment of a pressed pleated filter media packmade by the press assembly line of FIG. 1 where the trimming device isused to trim out part of one of the flow faces and sides and whereinultrasonic welding is used to connect pairs of adjacent pleat panels tothereby provide for pleats and prevent unfiltered air flow through themedia pack;

FIG. 57 is another embodiment of a pressed pleated filter media packshown in a circular shape wherein the trimming tool has been used toshape and cut away the width of adjacent panels to appropriate lengthsto create a circular cylindrical shaped media pack;

FIG. 58 is an isometric view of yet a further embodiment of a pressedpleated filter media pack wherein adjacent sets of panels are shiftedrelative to each other such that two of the sides are non-planar withadjacent panels being rotated relative to each other about an axis thatis perpendicular to the pleat panels;

FIG. 59 is an image of a pressed media pack panel where the panel is aparallelogram and the embossments in the form of grooves are shown to beskewed relative to the plane of the inlet and outlet faces;

FIG. 60 is an isometric illustration of two panels of a pressed pleatedfilter media pack where each panel has embossments and two sets ofembossments and wherein embossments on each panel project in a differentdirection from the plane of the panel;

FIG. 61 is an isometric view of two panels of a pressed pleated filtermedia pack wherein each panel contains embossments and wherein theembossments extend substantially less than a span between upstream anddownstream flow faces and/or creases/folds at opposed ends and alsowhere the embossments or grooves may project from different directionsfrom a plane of each panel;

FIG. 62 is an expanded isometric view of two panels of a pressed pleatedfilter media pack where one panel is pivoted and rotated away from theother panel for illustrative purposes to better show features, andwherein two different forms of tabs, one for pinching and securing pleatpanels together and another that extends from the panel to support anouter perimeter ring seal (that may form a complete ring loop that maybe rectangular or other annular shape) that can be used to seal a filtercartridge against a housing in which a filter element is installed whenin use;

FIG. 63 is an enlarged illustration of a portion of FIG. 62 taking aboutcircle 63;

FIG. 64 is an enlarged illustration of a portion of FIG. 62 taking aboutcircle 64;

FIG. 65 is an isometric view of two panels of a pleated filter mediapack where the filter media sheet has been formed by the press lineassembly of FIG. 1 and wherein integral tabs have been formed into thefilter media shape and that are embedded within an elastomeric seal(that would be understood to form a continuous loop for a housing sealsuch as a rectangular or annular shaped loop), with the adjacent pleatpanels being shown rotated and pivoted away from each other forillustrative purposes;

FIG. 66 is an enlarged view of a portion of FIG. 65 taken about circle66;

FIG. 67 is an isometric view of a side of a pressed pleated filter mediapack made by the press assembly of FIG. 1 and wherein some of theembossments formed also include an embossed graphic such as a writtenstatement for trademark branding or other information;

FIGS. 68 and 69; 70 and 71; and 72, 73 are three sets of differentisometric and end view profiles of portions of filter media sheetsshowing different embossing patterns and profiles that may be formedinto the filter media sheet and used in any of the embodiments disclosedherein;

FIG. 74 is an end view of a portion of a pressed pleated filter mediapack having an embossed panel with grooves according to one pattern thatis attached to and abuts an unpressed planar panel formed into theoverall sheet;

FIGS. 75, 76; and 77, 78 are additional isometric and end views of aportion of a filter media sheet through sections of embossments to showfurther embodiments of embossments usable with any of the foregoingembodiments;

FIG. 79 is an end view of a portion of pressed pleated filter media packshowing two adjacent panels each with embossments in the form oflongitudinal grooves wherein the embossments on adjacent panels arenested within each other in a region formed between adjacent panels;

FIG. 80 is an isometric view of two panels of a pressed pleated filtermedia pack that is particularly useful for pocket pleats wherein curvedembossments in the form of grooves are formed in conjunction with linearembossments in the form of grooves;

FIG. 81 is an isometric view of a panel similar to that shown in FIG. 80but wherein embossments extend from either side of the plane of thepanel;

FIG. 82 is an illustration of a side of a pressed pleated filter mediapack wherein the press panels have embossments projecting a full span ofthe pressed pleated filter media pack between an upstream face and adownstream face and wherein the embossments project from either side ofthe panels from which are embossed;

FIG. 83 is an isometric view of the embossed panel shown in FIG. 82 withthe embossments projecting from both sides in opposite directions fromthe panel;

FIG. 84 is an end view of a pressed pleated filter media pack accordingto a further embodiment wherein a combination of longitudinal groovesand curved grooves are provided in combination and wherein some of thegrooves project from the plane on one side of the embossed panels andother embossments project from the other side of the panels;

FIG. 85 is an isometric view of a panel used in the pack of FIG. 84showing the embossments projecting from both sides of the embossedpanel;

FIG. 86 is a perspective and partially schematic view of an alternativeembodiment of a multiple press machine assembly and line for formingpressed pleated filter media packs;

FIG. 87 is a perspective and partially schematic view of an alternativeembodiment of a indexable press machine assembly and line for formingpressed pleated filter media packs;

FIG. 88 is a perspective and partially schematic view of an alternativeembodiment of a rotating lobbed press machine assembly and line forforming pressed pleated filter media packs;

FIG. 89 is partially schematic, cross sectional view of an alternativeembodiment of a progressive die arrangement that can be employed in anyof the presses shown in FIGS. 1, and 86-88 according to variousembodiments;

FIGS. 90, 91 and 92 are isometric top and end views of an alternativeembodiment of an embossing plate for forming tapering grooves that isusable in the press assembly in line of FIG. 1;

FIGS. 93, 94 and 95 are isometric bottom and end views of a top embossplate usable with the bottom emboss plate of FIGS. 90-92 for formingtapering grooves;

FIG. 96 is an enlarged view of a portion of FIG. 95 taken about theindicated circle;

FIG. 97 is a perspective view of a portion of a pressed pleated filtermedia pack made a by the assembly and line of FIG. 1 and having pocketpleats and also ultrasonically point bonded pleat tips in accordancewith further embodiments of the present invention;

FIG. 98 is a perspective illustration of the filter media pack of FIG.97 being made showing the pleat pack and the next hinged embossed panelfor illustrative purposes;

FIG. 99 is a perspective illustration of an embossed pleated filtermedia pack and frame, wherein the media pack is formed via the press ofFIG. 1 or other press embodiments and together forms a brand to provideinformation to the consumer;

FIGS. 100-102 are schematic representations of parts of a press andpleat machine assembly line, including as a filter media press and acooperating welder and anvil according to an alternative embodiment thatmay be used as an alternative to corresponding structures shown in theschematic illustration of the FIG. 1 embodiment, with FIG. 100-102showing a folding sequence utilizing the cooperating welder and anvil inprogressive steps to form welded pocket pleats;

FIG. 103 is a schematic representation of a further alternativeembodiment that is the same as FIGS. 100-102, but additionallyillustrating and disclosing cutting in the filter media sheet withirregular cuts that can be welded by the welder and anvil along a cutseam;

FIG. 103A is a schematic end face view of an anvil usable to in theembodiments of FIGS. 103 and 104 showing rib projection tool with spacedapart rib projection elements for facilitating forming of pocket pleatsand seaming arcuate cut edges in an irregular shaped filter media pack;

FIG. 104 is a is a schematic representation of a further alternativeembodiment that is the same as FIG. 103, but alternatively illustratingand disclosing precutting the filter media sheet prior to pressing withcertain embossments;

FIG. 105 is an isometric illustration of an ultrasonic welder assemblythat can be incorporated and used at the end of the press and pleatmachine assembly line in the embodiment of FIG. 1 (e.g. for the anvil 86and welder 84), according to a further embodiment of the presentinvention;

FIGS. 106-109 are additional similar isometric views ultrasonic welderassembly shown in FIG. 105, with each figure showing a subsequentprogressive step in forming a folded pleat segment, and with certaincomponents removed relative FIG. 105 to better show the filter mediasheet;

FIG. 110-113 are enlarged isometric views (not all taken from sameperspective) of the anvil assembly and the sonotrode assembly along withthe filter media sheet and the incipient pleated filter media pack beingillustrated, with each figure showing a subsequent progressive step informing a folded pleat segment of the incipient pleated filter mediapack;

FIG. 114 is an enlarged detailed isometric view of the Y-axis actuatorand linear slide sub-assembly used for the anvil and previously shown inFIG. 105, but shown from a different perspective;

FIG. 115 is an enlarged detailed isometric view of the hold down gripperon the anvil assembly that is used embodiment of FIGS. 114 and 105;

FIG. 116 is a partly schematic top view of a welded creased and foldedpocket pleat formed from pleated filter media sheet immediately afterbeing cut and welded between an anvil and a sonotrode, with thesonotrode and the anvil being shown in cross section;

FIG. 117 is a partly schematic end face view of a further embodiment ofan anvil usable in the embodiment of FIG. 105 for forming an irregularshape pocket pleat filter pack;

FIG. 118 is a partly schematic end face view of a further embodiment ofan anvil usable in the embodiment of FIG. 105 for forming a simultaneouscut and weld seam to form an irregular shaped filter pack having arecess in the inlet or outlet face thereof;

While the invention will be described in connection with certainpreferred embodiments, there is no intent to limit it to thoseembodiments. On the contrary, the intent is to cover all alternatives,modifications and equivalents as included within the spirit and scope ofthe invention as defined by the appended claims;

DETAILED DESCRIPTION OF THE INVENTION

A. The Disclosure of PCT/US2016/047283 Filed Aug. 17, 2016, Entitled“Filter Media Packs, Methods of Making and Filter Media Presses”

Turning to FIG. 1, the first embodiment of the present invention hasbeen illustrated as an apparatus in the form of a press and pleatmachine assembly line 10, that processes a continuous filter media sheet12 that is being unwound from a filter media roll 14. It is noted that“assembly line” in this context does not mean linear but instead means amanufacturing process in which processing steps are conducted in aseries of different work stations typically in a sequence until a finalproduct is produced. In this instance, the final products produced are aplurality of pleated filter media packs 16 that are delivered onto aconveyor 18 via a shoot 20.

The machine assembly line extends generally between an upstream regionthat includes a media unwind station 22 where the filter media roll 14is placed to allow media to unwind and that is periodically replacedwhen the media roll is exhausted thereby temporarily shutting down theline, toward a downstream region where a pleater such as media packcollector 24 is located. The media pack collector 24 includes a trapdoor 26 to allow a produced filter media pack 16 to ride on the packshoot 20 to the conveyer 18.

In accordance with certain inventive aspects according to certainclaims, the machine assembly line 10 includes between upstream anddownstream regions a press 28 that comprises a cooperating pair ofstamping dies that include an upper stamping die 30 and a lower stampingdie 32. The press 28 further includes a ram 34 that drives the stampingdies 30 and 32 repeatedly into and out of engagement with each otherduring operation. As can be seen in the enhanced circle image, thestamping dies comprise mating female and male embossment features 36that are adapted to form embossments 38 into the filter media sheet 12as also illustrated by enlarged circle views.

The machine assembly line 10 further includes a media conveyingmechanism such as a conveyor such as cooperating rolls 40 that serve toadvance the filter media sheet 12 in a direction from the unwind station22 region toward the region of the pleat collector 24. These cooperatingrolls 40 may be located at multiple locations along the machine assemblyline but in this instance is shown located between the press 28 and thepleat collector 24.

It should be noted that the cooperating rolls 40 do not deform or formthe filter media in an embodiment, but instead will serve to grip thefilter media and move the filter media along a path 42 leading to themedia pack collector 24.

The cooperating rolls 40 may also be chilled to effectively cool theembossed filter media sheet after it has passed through the press 28. Inthis regard, stamping dies may also be heated and are preferably heatedto an elevated temperature as described herein such that during a dwelltime of the stamping dies the filter media is heat-pressed to set andheat-press the embossments 38 into the filter media sheet 12.

Additionally, or in the alternative, an optional oven or heater 44 maybe arranged upstream of the press 28 to preheat the filter media sheet12 and therefore make it more pliable for processing through the press28.

In an embodiment, the press may include a support table 46 upon whichthe lower stamping die 32 is removably mounted and fixed. The lowerstamping die 32 may thus be non-movable during operation.

Further, the ram 34 may include a hydraulic or electrical linearactuator 48 that drives shaft 50 in successive and repeated linearreciprocating movement. Shaft 50 at its end supports and carries theupper stamping die 30 which is driven linearly back and forth in closeproximity to the lower stamping die 32 with the filter media sheet 12trapped and pressed therebetween.

The linear actuator 48 may be supported via a support cage 52 that maybe self-supported or supported more preferably by the table 46 tomaintain the alignment between the upper and lower stamping dies 30, 32so that the respective male and female embossment features 36 in thestamping dies meet in cooperating and receiving fashion into each other.

The press and its linear actuator 48 and the cooperating advance rolls40 may be manually activated in an intermittent fashion whereby duringthe pressing operating the filter media sheet 12 is not advancing alongthe predetermined path 42 but is maintained stationary and when thepress and its stamping dies 30 and 32 are released with a largeclearance gap therebetween, then the cooperating advance rolls 40 may bedriven to advance the sheet to the next embossing location.

More preferably, this is automated and done with a suitable control suchas an electronic controller that may be a software programmed computerand/or a programmable logic controller. Controller 54 is shown to beconnected to the cooperating rolls 40 as well as the linear actuator 48to automate this intermittent activity such that the press is driveninto engagement heat pressing the filter media sheet 12 while thecooperating advance rolls 40 are not in driving engagement. Further, thecontroller 54 maintains the released and separated position of the upperand lower stamping dies 30, 32 while the cooperating rolls 40 are beingdriven. The controller 54 alternates between these two states. Further,the controller 54 will advance the filter media sheet a predetermineddistance each time and may be programmed or selected to provide regularintervals that may be equal intervals or alternatively variable distanceintervals for the various embodiments of filter media packs describedherein.

The controller 54 may also coordinate and actuate an optional roboticpart placer 56 that may be arranged along the line, preferably upstreamof the press 28 to locate and place tabs as herein described in certainembodiments with or without adhesive onto the filter media sheet 12 thatmay then be run through the press 28 and also pressed into engagementfor further securement. Such tabs are optional features used in some ofthe embodiments disclosed herein such as in those embodiments of FIGS.62-64 for example.

The press and upper and lower stamping dies 30, 32 include upper andlower emboss plates 58, 62 and may also include both at upstream anddownstream ends upper score bars 62 and lower score bars 64. The scorebars and the upper and lower emboss plates may provide for plateassemblies. The upper and lower score bars 62, 64 are preferablyprovided to also simultaneously press scores and thereby crease thefilter media sheet 12 both upstream and downstream from the embossments38 in the filter media sheet to form upstream and downstream scores 66,68 that afford the opportunity to provide creases that serve tofacilitate folding of the filter media. Folding at the creases providesthe pleated filter media pack 16 with embossed pleat panels 70 that havebeen pressed and unembossed pleat panels such as flat pleat panel 72that may not have been pressed and preferably are not pressed. As cangenerally be seen, the process forms a continuous sheet of alternatingembossed pleat panels 70 and flat pleat panels 72 that are joined toeach other through upstream and downstream scores 66 and 68 asindicated.

When the desired length of filter media sheet 12 has been generated andpassed through the machine assembly line 10 it may be manually cut ormore preferably cut via an automatic pack cutting knife 74 that may bealso in communication with the controller 54 to cut at appropriate timesrelative to the advancing cooperating rolls 40 that advance the filtermedia sheet along the predetermined path 42. Once the controller 54 hasdriven the cooperating rolls 40 a predetermined distance correspondingto the desired length of filter media sheet 12 usable for the pleatfilter media pack 16, the pack cutting knife 74 may be actuated to cutthrough transversely and preferably perpendicularly to the travel path42 to cut the sheet to length for each of the filter media packs 16.Preferably this is also done during intermittent stoppage but may alsobe operated on a continuous basis in which the knife could move at anangle other than perpendicular to the path 12 to move at the same speedin the direction of the path during cutting.

Another optional feature that may be used in issues to make certainfilter media pack embodiments is a trim knife 76 that may be used totrim one or both of the side edges 78, 80 of the media as schematicallyindicated in FIG. 1. For example, this trim knife 76 may be used to trimedges such as shown in FIG. 41 or as otherwise used to trim edges toform the shapes shown in FIGS. 45-48 for example; as well as additionalembodiments shown for example in FIGS. 56 and 57.

Trim knives 76 may be provided on opposing opposite sides or proximatethe side edges 78, 80 on opposite sides of the filter media sheet 12 toperform these operations. The trim knife 76 may be operated while themechanized media advance roll 40 is operating or alternatively may cutand perform a trimming operation in a mechanized fashion while thefilter media sheet 12 is stopped and during pressing operation of thestamping dies 30, 32 when they are engaged. Greater precision andcontrol of knife 76 can be realized during stoppage.

Additionally, another further optional and desired feature is theability to have adhesive applicators 82 that may also be in electricalcommunication with the electronic controller 54 to dispense adhesivesuch as hot melt, urethane, glue or other such suitable adhesive uponthe filter media sheet 12 at desired locations. The adhesive applicator82 may thus dispense adhesive only while the rolls 40 are advancing thefilter media sheet 12 but advantageously can also be operated during theintermittent stopping to apply adhesive while the filter media sheet isstopped such as applying across the filter media sheet if additionalstitch feeds are desired. The adhesive 82 may also be applied atdifferent locations and there may be more than one adhesive applicator82 such as on opposed side edges 78, 82 that may apply adhesive onopposed side edges 78, 80 of the filter media sheet 12 in order to seamthe side edges and form pocket pleats. For example, the adhesive appliedby the adhesive applicator 82 upon the edges of filter media sheet 12may seam together and form a sealed seam on opposed side edges to ineffect form a pocket pleat such as can be seen for example in theembodiment of FIG. 97. In FIG. 97 adjacent edges of an embossed paneland a flat panel are shown to be seamed together which may beultrasonically bonded or alternatively through adhesive.

Additionally, or in the alternative, the adhesive applicator 82 may alsoapply adhesive at select locations such as shown in FIG. 98 wherevarious dots are illustrated. These dots may be adhesive applicationsfor point bonding or which may alternatively represent ultrasonicbonding locations. This may provide for additional structural integrityto the pleated filter media pack 12 to prevent panels from shiftingrelative to each other during use.

Downstream of the press and optional bonding, various forms of pleatersmay be used including pleat collectors that simply fold the filter mediapack.

One form of pleat collector as illustrated is in the form of anultrasonic plunge welder 84 that works in conjunction with an ultrasonicanvil 86 that are configured with ultrasonic horn features that mate andcontact with each other to ultrasonically bond and weld adjacentportions of the filter media sheet together. The plunge welder 84 andthe anvil 86 may be driven towards and away from each other withadjacent pleat panels 70, 72 therebetween. The plunge welder 84 andanvil may also be used to form bonds at seams and/or form point bondsthrough ultrasonic welding and/or thereby form the features such aspocket pleats as shown in FIGS. 97 and 98. Each of the plunge welder 84and the anvil 86 are movable toward and away from each other and may bemoved away from each other to allow the plunge welder 84 to allowadvancement of pleat panels of the filter media sheet and to weldfeatures upon the immediate pleat panels of the sheet of the in-processfilter media pack 16 that is positioned in media pack collector 24.

The movement of the plunge welder and the anvil may also be coordinatedrelative to the action of the cooperating rolls 40 and may be activeduring intermittent stoppage and can also be operated during advancementof the filter media sheet along the path 42. The plunge welder 84 mayinclude suction and a vacuum on its face in order to pick up andtemporarily secure the pleat panel to itself and facilitates folding ofthe filter media sheet along the upstream and downstream scores 66, 68that are created by the corresponding score features of the upper andlower score bars 62, 64.

Yet another optional feature that may be employed is the ability to usea laminate sheet 88 such as an additional filter media sheet, a scrim, asupport, a screen such as expanded metal for support or other suchlaminate feature which may be desired to be employed. In someembodiments it may be desired to have two layers of filter media sheetto provide for a first level of filtration to capture larger particlesand thereby a less efficient upstream surface to the filter media sheetand a more efficient downstream layer to the filter media. Accordingly,a laminate sheet 88 may be dispensed from laminate roll 90 to overlayeither above or below filter media sheet 12 and also run through thesimilar components including the press 28 of the machine assembly line10. Accordingly, with this configuration the laminate sheet 88 wouldalso be pressed with the same embossment features and embossment 38 asin the filter media sheet 12.

Turning now to FIGS. 14, 15, and 16, the details of the pressed filtermedia sheet 12 formed by the machine assembly line 10 illustrated inFIG. 1 and its component as illustrated in FIGS. 2-13 can be seen withadditional detail. In FIG. 15 it should be noted that only a partialsection of the filter media sheet is shown and break lines on the topand bottom are illustrated to show that additional embossments areplaced side by side. From the foregoing description it will be readilyunderstood how the filter media sheet 12 with the embossments 38 areformed and now detail will be provided to those formed features.

The embossments 38 take the form of projecting ridges 182, when viewedfrom one side such as top side in the case shown in FIG. 15, and thatform corresponding grooves 186 also defined along the underside of theembossments 38 as well as grooves 186 that are formed between theprojecting ridges 182. Additionally, on the bottom side, correspondingridges 182 are formed with grooves 186 on the opposite side.

Typically, the embossments 38 extend a full length of the embossed pleatpanel 70 and between adjacent but spaced flat plate panels 72 as shownin FIGS. 15 and 16, which typically is at least 90% of the length spanof the embossed pleat panels 70 between upstream and downstream scores66, 68 that provide for pivoting hinges at upstream and downstreamlocations indicated at 188, 190. In this manner, the upstream hinge 188allows the upstream flat pleat panels 72 illustrated in FIG. 16 to swingand overlay the bottom side of the embossed pleat panel 70 shown in FIG.16; whereas the downstream hinge 190 is oriented to allow the downstreamflat pleat panel 72 to overlay the top side 184 with the orientationshown in FIG. 16. It is understood that the top side 184 and bottom side185 are reversible in that the top side may be the bottom side and thebottom side may be the top side.

In the elevation indicated in FIG. 16, preferably the upstream hinge 188is located at a different elevation relative to the pivoting hinge whenthe filter media sheet is viewed inside elevation. Specifically, withthe filter media sheet or embossed panel lying flat, the upstream hingeis shown to be positioned below the downstream hinge 190. This allows avertical gap to allow for folding and pleating of the filter media sheet12 to accommodate the height of the embossments 38. Preferably, theupstream and downstream hinges 188, 190 are spaced and separated fromeach other a vertical distance with the orientation shown in FIG. 16preferably at least 50% of height of the embossments and more preferablyat least 75% of the embossments.

Further, the ends of the embossed regions as shown in FIGS. 15 and 16may additionally include tapered ends at the opposite ends of theembossments that lead into and merge into the hinges 188, 190.Additionally, the hinges are also provided with smaller size grooves 194extending perpendicular to the embossments that provide for additionalflexibility in the hinge structure. These grooves 194 may be formed bythe additional triangular groove and triangular ridge projections 174,176 as shown with reference to FIGS. 12 and 13, while the main scorelines 66, 68 can be formed by the triangular ridge and triangular groove170, 172 also shown in FIGS. 12 and 13.

To help facilitate the formation of the tapered ends 192, the embossingfeatures 36 shown on the stamping dies may also have correspondingtapered end sections as shown for example in the embodiment of theemboss plates of FIGS. 17-19.

To recap and provide additional further details on the operation of theassembly line and the method of forming a pleated filter media pack witha filter media sheet, it can be seen with reference to FIGS. 1-16 thatthe method comprises pressing embossments 38 into the filter media sheet12 repeatedly with the stamping dies 30, 31. Thereafter, the filtermedia sheet 12 is pleated utilizing the upstream and downstream scores66, 68 that form corresponding hinges 188, 190 that facilitate foldingand thereby pleating of the filter media sheet into the pleated filtermedia pack 16.

An additional view of such a filter media pack for example is shown inFIG. 43 where it can be seen that this methodology increasing the filtermedia sheet at spaced intervals forms the filter media pack 16 toinclude a plurality of pleat tips 196 at both flow faces 198, 200 inwhich one flow face is the upstream flow face and one face is thedownstream flow face. By creasing the filter media sheet at spacedintervals to form the pleat tips, the embossments 38 can be seen asextending and disposed at least partially between the pleat tips 196 asshown in FIG. 43.

When done in this fashion, where the intervals are uniformly spaced andwith the pleat (e.g. pleat panels) extending between the pleat tips atthe respective inlet and outlet faces, the distance between the pleattips at the inlet face and the pleat tips at the outlet face may remainconstant and thereby form a cuboid shape for the filter media pack 16shown in FIG. 43.

However, with the pressing methodology it can also be accomplished toform the intervals at non-uniform spacing wherein the pleats extendbetween pleat tips at the inlet face and pleat tips at the outlet facewith a distance bearing and creating pleated filter media packs that areirregularly shaped with a region of the inlet face and the outlet faceextending obliquely relative to the extent of the pleat panels 70, 72such as shown in the similar but alternative embodiment of FIG. 44showing a pleat pack 202 where the flat pleat panels 72 are longer thanthe embossed pleat panels 70. Accordingly, the flow faces 204 and 206,while they may extend parallel to each other, extend obliquely and notperpendicular (as in the case of FIG. 43) relative to the embossed pleatpanel 70 and flat pleat panel 72.

In both embodiments of FIGS. 43 and 44, it can be seen that, relative tothe advancement of the filter media sheet 12 along the travel path 42shown in FIG. 1, the extent of the creasing formed by scores and therebythe corresponding pleat tips 196 extend in a direction that istransverse and typically perpendicular to the travel path. Also,advantageously, is that not every panel needs to be processed whichprovides additional speed to the overall process in that the pressing ofthe embossments 38 will be done only into the embossed pleat panels 70and the pressing may be skipped on the flat pleat panels in anembodiment which also causes the first and second embossed and flatpanels to mismatch. This procedure is repeatedly or successivelyconducted to form the overall pleat packs 16 and 202 shown in FIGS. 43and 44 for example.

In a preferred operation of the machine assembly line 10 of FIG. 1, thefilter media sheet 12 is intermittently and successively advanced andstopped along the travel path 42. While the filter media sheet 12 isstopped, the pressing is conducted via the press 28 such that the filtermedia sheet 12 cannot advance if the press is stationary, and while thefilter media sheet is advancing, the filter media sheet passes freelythrough the stamping dies 30 and 32 which are separated by a large gapfor clearance and not in engagement such as shown in the currentcondition in FIG. 1. When the stamping dies come together in the pressedand engaged position though, as shown for example in FIG. 13, that iswhen the filter media sheet cannot pass, travel or advance relative tothe press.

An advantage of this intermittent advancing and stopping operation isthat further operations can be conducted either upstream or downstreamof the pressing dies. While the filter media sheet is stopped, otherprocessing steps and their control are easier and more precise as suchoperations do not need to be moved at the same speed as the filter mediasheet but may be kept in a stationary position without needingcoordination with the speed of the filter media sheet. For example,during stoppage bonding of adjacent pleats formed by pleating can beconducted such as by the plunge welder 84 and anvil 86.

Additionally, or alternatively, during such stoppage of the filter mediasheet, the edges of adjacent pleats may be trimmed to include one orboth of side edges 78 and 80.

Additionally, the pleat tips for at least one of the inlet and outletfaces may be cinched and/or pressed together such as like by ultrasonicbonding that may also be performed by the plunge welder and anvil 84, 86with such features being shown for example in the pleated filter mediapack shown in FIG. 97. Additionally, during stoppage the robotic partplacer 56 may attach components to adjacent panel to provide forstructural support or facilitate better integral attachment of anintegral housing seal as shown with respect to various embodiments.

Preferably, and for the most simplistic type of operation, the upper andlower stamping dies 30, 32 including their respective plates are movabletoward and away from each other with linearly reciprocating movement ofthe plates with the respective female and male embossment featuresreceived into each other with the filter media sheet therebetween. Withthis configuration, the respective plates 58, 60 extend in parallelplanes.

An advantage to using the linearly extending grooves and the linearlyextending ribs to provide for the male and female embossment features asshown in the emboss plates of FIGS. 2-10 is that the correspondingembossments 38 formed into the filter media sheet can maintain aconsistent depth and height for at least 90% of the length of thecentral portions of the embossments that extend between thecorresponding pleat tips that are formed during pressing and pleating.This provides a maximum ridge strength and structural integrity suchthat the pack when formed such as shown in FIG. 43 or 44 maintainsconsiderable strength when subjected to an air flow in application.Specifically, the spacing between the adjacent pleat panels ismaintained during air flow, and the pleats do not collapse or blind offon each other due to the embossments which provide for structuralsupport and integrity of the pleats. This maintains open and good airflow between adjacent pleat panels due to little contact or minimalcontact between adjacent pleat panels to maximize the usage of thefilter media contained within the filter media sheet.

The embossments also provide in effect a corrugation pattern thatprevents the filter media sheet from bending in at least one dimensionproviding for additional strength and support for the pleated filtermedia pack. Thus, by extending the embossments over the full length suchas at least 90% of the length, good structural integrity of the pleatedpack is realized. This is particularly advantageous for deep pleatfilter media packs that have a pleat depth (e.g. span between inlet andoutlet faces) of greater than 6 cm and pleat packs that may be greaterthan 10 cm or even 20 cm or more. Pleat packs may be formed that have apleat depth between 1 cm and 180 cm, but again this is particularlyadvantageous for the deep pleat media packs aforementioned.

Also, during a preferred operation, the filter media sheet 12 is engagedand actively pressed with force between the upper and lower stampingdies 30, 32 wherein the stamping dies can be separated in the engagedand pressing position by a gap equivalent to but more preferablyslightly less than a caliper thickness of the filter media sheet thatmay be a gap of between 80- and 99% of the caliper thickness of thefilter media sheet. This gap can be controlled with stop abutments onthe plates of by way of the amount of pressure applied to the presses inwhich the media content of the filter media sheet limits the pressing.

During pressing, a significant dwell time may occur that is between 0.2-and 300 seconds and preferably between 1- and 15 seconds to ensureadequate formation of the embossments and maintain the shape. This ineffect presses and holds the media to press the features akin to anironing operation.

Also, preferably, the tapered end portion in the form of tapered ends192 are formed into opposed ends of the central portions of theembossments 38 such as shown in FIG. 19, but also shown in the completedfilter media packs of FIGS. 43 and 44 with the tapered end portionsextending toward the respective pleat tips 196. This provides for alarger air flow entrances and air flow exits at the respective inlet andoutlet flow faces 204 and 206.

To facilitate formation of the most advantageous grooves to provide formaximum filtration capacity, the corresponding grooves and ribs of theembossment features on the die 36 and the corresponding embossments 38formed into the sheet press embossments have a length greater than 5 cmwith a width of at least 2 mm and a depth of at least 2 mm. Thesemeasurements are shown in FIGS. 16 and 16 a as length L, width W, anddepth D. It is noted that width is measured in these embodiments betweenthe center of adjacent tips of the ridges and the depth is measured fromthe tip of a ridge to a groove bottom.

Preferably, the embossments (and corresponding ridges and/or grooves)have a depth of between 2 mm and 8 mm, and a width of between 2- and 16mm. The length will depend upon the overall span or length of the filtermedia pack between upstream and downstream pleat tips, but typicallycomprises at least 90% of the length as described herein, although otheralternatives are possible.

Additionally, to sufficiently set the pleats and maintain the embossedshape, heating of the filter media sheet for the pressing to atemperature below the glass transition point of the fibers of the mediais conducted such that the fibers are not melted or bonded together dueto the heating of the filter media sheet. For example, the heatingcomprises elevating the temperature of the filter media sheet to between65- and 125° C. for medias that comprise at least 50% cellulose fibersby weight; between 65- and 205° C. for medias that comprise at least 50%fibers by weight including at least one of polypropylene, polyester ornylon fibers. These are typically the most commonly envisioned fibersemployed in a filter media sheet, but additional types of fibers andmaterials may be used including glass fibers and a variety of otherpolymeric materials that are known to one of ordinary skill in the artand/or that are used in conventional filter media sheets. While thepress is preferably heated and heats the filter media sheet and may bethe sole source of heat, additional heating may be conducted such aspreheating the filter media sheet prior to entering the stamping dies.Again, active cooling of the filter media sheet such as by the advancerolls or by running through a cooling station may be conducted afterbeing pressed by the heated stamping dies.

Another advantage of using the press may be realized in certainembodiments, especially with the configuration of the width and depth ofthe embossments in that the filter media sheet can be stretched at theembossments to provide for an increased airflow permeability in thepressed region of the filter media sheet. These pressed regions andembossments may have the fibers pulled apart and not compressedaccording to certain embodiments. Specifically, it has been found that afilter media sheet can be stretched with the fibers slightly separateddue to the pressing operation when compared to the unpressed filtermedia sheet or the unpressed flat panels that are formed betweenembossed panels.

For example, due to the stretching the pressed air flow permeability isat least 110% greater than the unpressed air flow permeability measuredby a TAPPI T251 air flow permeability test. Preferably the pressed airflow permeability may be between 125- and 500% greater than theunpressed air flow permeability.

As a consequence, and when used in the embodiment where there arepressed regions and unpressed regions such as the embossed pleat panels70 and the flat pleat panels 72, different filtering characteristicregions may be formed in the pleated filter media pack. The pressedregion may comprise between 20- and 80% of the pleated filter media packwhereas the unpressed region may comprise the remainder of between 20-and 80%. This provides the opportunity to loosen up a more restrictivemedia and provide for a region that is slightly less efficient but moreair permeable in the embossed pleat panels and a region in the flatpleat panels that are more restrictive to air flow but have a higherefficiency.

In terms of materials, the filter media sheet preferably comprises atleast 10% polymer fibers by weight and more preferably at least 20%polymer fibers by weight and most preferably at least 50% polymer fibersby weight although other possibilities are possible.

The polymer fibers may comprise at least one of a fluorinated polymer,PVDF, polypropylene, polyester and nylon which are common materials usedin filtration medias but again other materials are possible. The filtermedia sheet may also alternatively comprise at least one of thefollowing media fibers: wet-laid microglass, nylon, polypropylene,polyester, wet-laid cellulose and wet-laid polymer. These fibermaterials may be used alone or in conjunction with each other.

The filter media fibers include fibers having a diameter size of lessthan 100μ and preferably less than 50μ and most preferably less than 20μin more efficient medias. These fiber materials may be used alone or inconjunction with each other.

For most typical filtration applications, the filter media sheet 12prior to pressing has an air flow permeability of between 2 and 400 CFMfor most filtration applications (including liquid filtration at thelower range end), and more preferably between 10 and 150 CFM for mostair filtration applications (measured by ASTM D737-04(2012) standard,commonly tested with TEXTEST Model FX3300 instrument); and an initialgravimetric efficiency of between 50% and 100% for ISO 12103-1, A2 FineTest Dust made by Powder Technologies having a location in Arden Hills,Minn. (measured by ISO 5011 standard), and a caliper thickness ofbetween 0.2 and 7 millimeters, and more preferably between 0.2 and 1millimeters.

Turning now to FIGS. 2-5 and FIGS. 7-10, the cooperating and matingupper and lower emboss plates 58 and 60, as employed in the press 28shown in FIG. 1, are shown in larger and greater detail. In FIGS. 2-5,the upper or top stamping die in the form of embossing plate 58 isillustrated to include a planar body in the form of a flat plate 100into which a plurality of embossment features 36 are formed to include aplurality of teeth and ridges 102 and grooves 104 that extendlongitudinally between an upstream end 106 and a downstream end 108. Thegrooves 104 extend generally parallel and in spaced relation and areformed between the ridges 102 in this embodiment. The teeth and ridges102 and the grooves 104 are sized and configured to be closely receivedwithin corresponding grooves and ridges formed on the bottom embossplate 60 shown in FIGS. 7-10 (see description below).

The upstream and downstream ends 106, 108 preferably have a plurality ofbolt holes 110 that allow for attachment of score bars as can be seenfor example in FIGS. 12 and 13. Additionally, bolt holes 112 areprovided for receiving bolts that provide for attachment to the carriage31 of the upper stamping die (See FIG. 1.)

Longitudinal and extending holes extend between front and back sides114, 116 and are indicated as heating channels 118 that can eitherreceive a heating element or alternatively be hooked up to a fluidcircuit to circulate hot fluid to facilitate heating of the emboss plate58 to the desired temperature to facilitate heat pressing of the filtermedia sheet.

Further, pilot structures 120 may be provided that interact and alignwith corresponding pilot structure on the upper stamping die carriage 31to facilitate better alignment and precise alignment of the upper embossplate 58 relative to the lower emboss plate 60 of the lower stamping die32 shown in FIG. 1.

Turning then to FIGS. 7-10, the lower emboss plate 60 is illustrated ingreater detail which is quite similar to that of the upper emboss plateshown in FIGS. 2-5 and is configured to matingly receive with the upperemboss plate with the teeth and ridges of the upper emboss plate beingreceived within the grooves of the lower emboss plate and the teeth andridges of the lower emboss plate being received within the grooves ofthe upper emboss plate. It is also understood that the lower embossplate rather than being mounted to the upper stamping die carriage wouldbe instead nested and received within a fixture 33 of the lower stampingdie 32 shown in FIG. 1, which may simply be the table top or otherstructure mounted on table 46 shown in FIG. 1.

In FIGS. 7-10, the lower or bottom stamping die in the form of embossingplate 60 is illustrated to include a planar body in the form of a flatplate 130 into which a plurality of embossment features 36 are formed toinclude a plurality of teeth and ridges 132 and grooves 134 that extendlongitudinally between an upstream end 136 and a downstream end 138. Thegrooves 134 extend generally parallel and in spaced relation and areformed between the ridges 132 in this embodiment. The teeth and ridges132 and the grooves 134 are sized and configured to be closely receivedwithin corresponding grooves and ridges formed on the top emboss plate58 shown in FIGS. 2-5 (see description above).

The upstream and downstream ends 136, 138 preferably have a plurality ofbolt holes 140 that allow for attachment of score bars as can be seenfor example in FIGS. 12 and 13. Additionally, bolt holes 142 areprovided for receiving bolts that provide for attachment to the table inFIG. 1

Longitudinal and extending holes extend between front and back sides144, 146 and are indicated as heating channels 148 that can eitherreceive a heating element or alternatively be hooked up to a fluidcircuit to circulate hot fluid to facilitate heating of the emboss plate60 to the desired temperature to facilitate heat pressing of the filtermedia sheet.

Further, pilot structures 150 may be provided that interact and alignwith corresponding pilot structure on the table and fixture tofacilitate better alignment and precise alignment of the upper embossplate 58 relative to the lower emboss plate 60 as shown in FIG. 1.

Turning to FIGS. 12-13 it can be seen that upper and lower score bars62, 64 are removably and adjustably mounted to both the upper and loweremboss plates 58, 60 by way of bolts 152 that are shown in FIG. 13. Thescore bars include oblong adjustment slots 154 that allow the score barsto be moved vertically upward and downward to allow positioning of thescore lines when conducted on the filter media to be at a higher orlower end relative to the embossments that are formed, which isadvantageous in pleating operations of the embossed pleats formedherein. Further, it can be seen that when engaged as shown in FIG. 12athere exists a gap 156 between the upper and lower score bars 62, 64 toaccommodate the filter media sheet.

In this regard, it should also be appreciated that the respective teethand ridges 102, 132 and corresponding grooves 104, 134 of the upper andlower emboss plates 58, 60 when engaged do not contact each other, butinstead there is a similar gap to gap 156 that can in some embodimentsbe formed due to the fact that the upper and lower emboss plates 50 and60 have corresponding abutment surfaces 122, 124 both on front and backends that run traverse and preferably perpendicular to the score barsthat will contact each other before bottoming out occurs to ensure a gapthat is of the desired width to accommodate the filter media sheet.Additionally, shims may be placed on either or both of the abutmentsurfaces 122, 124 and form the abutments to adjust the gap accordingly,to accommodate different filter media caliper thicknesses.

With continuing reference to FIGS. 12 and 13, it can be seen that theupper and lower score bars 62, 64 are each made of similar andindividual and cooperating score bar members 158, 160, either which maybe an upper or lower score bar. Score bar member 158 includes a groove162 that receives a projection 164 extending from the other score barmember 160.

Further, a preferred configuration formed on the outside surface of thecorresponding groove and projection includes tapering walls includingtapering walls 166 formed on the grooved score bar member and taperingwalls 168 formed on the ridged score bar member 160 that match and alignwith the tapering walls 166 such that a consistent gap 156 is maintainedtherebetween.

Additionally, within the groove and projection features, additionalgrooves and projections are provided. For example, the grooved score bar158 also includes a central projection in the form of a triangular ridge170 that is configured to form a corresponding score line to form acorresponding hinge in the filter media sheet for forming pleats. Thetriangular ridge is received within a corresponding triangular groove172 that is formed within the projection 164 of the ridged score barmember 160. Additionally, on either side of the triangular ridge, a pairof triangular grooves 174 are provided that receive the correspondingpair of triangular ridge projections 176 from the other score barmember. These create additional flexibility if desired in the overallhinge structure of the filter media sheet when used to form a pleatedfilter media pack.

As can be seen, the grooved score bar members 158 are provided asattached to the lower emboss plate 60 of the downstream end with theridged score bar member 160 attached to the upper emboss plate 58; whileon the upstream end 106, 136 the grooved score bar members 158 areprovided as attached to the upper emboss plate 58 with the ridged scorebar members 160 connected to the lower emboss plate 60. By virtue ofthis configuration, the hinges are inverted one another when formed intothe filter media sheet as will be seen with reference to FIG. 16.

While the abutment surfaces 122 and 124 may stop and thereby provide alimit to a maximum amount of compression, the stop and abutment surfaces122 and 124 may not come into contact with one another, but may actuallybe separated by a gap even when in the pressed and engaged position withthe filter media sheet being pressed by the embossment features 36 ofthe respective upper and lower stamping dies 30, 32. In particular,rather than controlling the gap or thickness by contact with theabutment surfaces 122, 124, the ram 34 and its linear actuator 48 mayhave a predetermined or preset pressure to provide a predeterminedpressure in pounds per square inch to the filter media sheet.

The filter media sheet typically does not extend over the abutmentsurfaces 122, 124 in a preferred embodiment, although other alternativesare possible, including having trimming knives that engage on theabutment surfaces. By using a controlled pressure, a desired amount ofstretch may be imparted to facilitate stretching of fibers and increasedair flow permeability to provide a filter element that may have anincreased life span due to the increased air flow permeability. Thereason is that filter expiration for lifespan is often determined by therestriction or pressure drop at predetermined air flow parameters. Byopening the media through stretching and providing for increased airflow permeability, that will delay the point in which a filter reachesthe restriction or pressure drop thereby extending the overall life ofthe filter and its lifespan.

Further, to form the filter media sheet having the width, depth andlength dimensions shown in FIGS. 15, 16 and 16 a, it will also beappreciated with reference to FIGS. 5, 6, 10, and 11 that the same widthand length and depth dimensions will also apply to the teeth andcorresponding grooves on the upper and lower emboss plates 58 and 60.This makes sense because the shape of the embossed features 36 in thestamping dies generally match the embossments 38 formed in the filtermedia sheet. However it is noted that in the filter media sheet, and dueto flexibility and some memory of the filter media that the edges andfeatures of the filter media including the corresponding ridges andvalleys such as grooves, may not have sharp corners but may be morerounded in profile. Referring back to FIGS. 10 and 11, it can generallybe seen that the shape of the grooves include the maximum width(designated as width W measured between peak tips of ridsges), but alsohave a groove bottom which defines a minimum width Wmin that in anembodiment may be 20- to 50% of the normal width W. Additionally, eachof the teeth or ridges 102 has a tip having a width Wt that is smallerthan the width Wmin to allow room for the filter media to pass alongeither side of the teeth without being cut or rendered non-functional.Typically, the tooth width Wt is less than 75% of Wmin and typically 50%or less in various embodiments herein, but the ultimate shape orthickness will depend in part upon the desired caliper thickness of thefilter media sheet being run. As shown in the first embodiments shown inFIGS. 2-13, the bottoms of the grooves 104, 134 may be flat and the tipsof the teeth and ridges 102, 132 may also likewise be flat.

Turning next to the emboss plates shown in FIGS. 17-22 according to yetanother embodiment of the present invention, it will be understood thatthese emboss plates 210, 212 are structurally the same as those shown inthe corresponding embodiments of FIGS. 2-13 and also usable in the press28 of FIG. 1 such that the afore-described features of the priorembodiments are applicable to this embodiment as well. However,additional features and distinctions will be discussed below.

As can be seen in FIGS. 17 and 18, emboss plate 220 is formed with anadditional feature in the form of tapered ends 214 that are formedintegral with the embossing feature and at corresponding upstream anddownstream ends of the emboss plates. Further, the teeth tips may alsoinclude a non-flat feature such as a linearly extending indentation 216that may have some advantages with certain medias. Turning to FIG. 20,the emboss plate 212 matches and mates with the emboss plate 210 asshown in FIG. 17. This emboss plate 212 is similar to those of previousembodiments, but it is noted that the pleat tips while flat do not havesharp corners but are rounded at rounded tips as shown in FIG. 22.

Turning next to FIGS. 23-28, further embodiments of cooperating andmating emboss plates 220, 222 are illustrated that also include aV-shaped or tapering groove profile according to a further embodiment ofthe present invention. It will be understood that emboss plates 220, 222are structurally the same as the embodiments of FIGS. 2-13 and alsousable in the press 28 of FIG. 1, such that the afore-described featuresof the prior embodiments are applicable to this embodiment. However,additional features and distinctions will be discussed below.

The primary additional distinction and feature is that each embossmentfeature tapers from upstream and downstream ends with a widening Vprofile at the upstream or inlet face (as well as the outlet face) inthe eventually formed media pack to allow for greater air flow into thefilter media pack and thereby funnel airflow into the media pack.Specifically, it can be seen that groove sidewalls 224 taper from theupstream end to the downstream end as shown in FIG. 25 thereby providinga narrower groove width at one end as compared with the other for theemboss plate 220. Similarly, the corresponding and matching emboss plate222 also has tapering groove sidewalls 226 as shown in FIG. 28. Thegrooved sidewalls 224, 226 thus do not extend parallel to the travelpath 42 when employed in the press 28 of FIG. 1, but extend at anoblique path to provide for the tapering grooves. Further, it is notedthat with this profile some of the embossments and their defined groovesformed in the resulting filter media pack will have a wider opening atthe inlet end while some of the grooves will have a wider opening at theoutlet end.

Turning next to the embodiment of FIGS. 29-34, further embodiments ofemboss plates 228, 230 are illustrated, where it is understood thatthese are structurally the same as the embodiments of FIGS. 2-13 andalso usable in the press 28 of FIG. 1, such that the afore-describedfeatures of the prior embodiments are also applicable to thisembodiment. However, additional features and distinctions will bediscussed.

Referring to these figures, it can be seen that a tapering group profileand tapering tooth profile is provided for both of the emboss plates228, 230. Specifically, it can be seen that the groove bottom and teethtips 232, 234 each taper from one of the upstream and downstream ends tothe other end of the emboss plate 228 which provides for taperingsidewalls 236 between upstream and downstream ends. As can be seen, thegroove bottom and teeth tips may also be rounded in this design, but itcan also be seen that the groove bottom width Wmin in this embodimentvaries and widens from one end to the other and narrows from that end tothe first, as depicted in FIG. 31. Additionally, the same and matchingfeatures apply to emboss plate 230 shown in FIGS. 32-34 with similarvariable width groove bottoms, 238 variable width teeth tips, 240, andtapering sidewalls 242.

Turning next to FIG. 35, a further embodiment is illustrated in partlyschematic form of upper and lower emboss plates 244, 246, that are alsostructurally the same as the embodiments of FIGS. 2-13 and also usablein the press 28 of FIG. 1 such that the afore-described features of theprior embodiments are applicable to this embodiment. However, additionalfeatures and distinctions will be discussed. The upper and lower embossplates 244, 246, in this embodiment, have a curved profile to providecurved male and female embossment features, including curved embossmentfeatures 248, 250 on the respective plates that also extend betweenupstream and downstream ends where respective score bars 252 areschematically indicated. One of the plates has a concave press surfacethat receives and provides a nest for the convex press surface 256. Anadvantage of using this design is that it may also impart a non-planaror curvature to the resulting filter media pack and filter media sheetto form the filter media sheet yet in a further dimension in addition tothe dimensions conducted by the embossments.

Yet a further embodiment of emboss plates 260, 262 are illustrated inFIGS. 90-96 where it will be understood that these are structurally thesame as the embodiments of FIGS. 2-13 and also usable in a press 28 ofFIG. 1, such that the afore-described features of the prior embodimentsare also applicable to this embodiment. However, additional features anddistinctions will also be discussed.

In this embodiment, a unique pattern of tapering grooves andcorresponding tapering teeth 264, 266 are provided in emboss plate 260with the depth of the tapering grooves and width of the tapering groovesboth varying as the plate extends from one end to the other. It can beseen that a first set of tapering grooves narrow in width and depth froman upstream end to the downstream end, while a second set of taperinggrooves narrow in depth and width from the downstream end to theupstream end. Further, the mating emboss plate 262 has tapering profiledteeth 268 that are adapted to be received in the tapering grooves 264with narrow slit grooves 270 illustrated, for example, in FIG. 96.

Turning next to FIGS. 38-41, it can be seen that various forms ofembossments and profiles may be created into the filter media sheet 12using the machine assembly line 10 of FIG. 1. It will be understood thateach of the embodiments shown in FIGS. 38 and 41 is structurally similarto the embossed sheet that is shown in FIG. 1 and, accordingly, theafore-described features of the prior embodiments are also applicable tothese embodiments. However, additional features and distinctions willalso be discussed.

Turning first to FIG. 38, an embossed filter media sheet 272 isillustrated to include embossed and non-embossed, unpressed or flatpanels 276 which are separated from one another by full creases dividedby score lines 78. Embossments are provided which define grooves 280which are schematically indicated and run perpendicular relative to thescore lines 278. However, the grooves in this embodiment only extend apartial span between upstream and downstream score lines 278 of theembossed panels 274. Thus, these are only partial length grooves 278rather than full length grooves. However, the grooves overlap and afirst set of the grooves 280 extend from the upstream score line to anoverlap in a middle region with a second set of grooves 280 which extendfrom the downstream score line 278. These grooves may terminate at least15% short of the upstream or downstream crease created by the respectivescore lines. As a result, an upstream set and a downstream set ofgrooves are laterally offset from each other, but have overlappingportions such that in any plane perpendicular to the travel direction ofthe media during pressing, the plane extends at least through one of theupstream and downstream sets of grooves to provide a continuous bridgestrength through a middle region of the embossed sections, thuscollectively the grooves and embossments extend at least 90% of thelength or span between creases when two adjacent grooves or embossmentsare considered together. With this configuration, less of the sheet mayneed to be embossed and the grooves also do not need to extend fullywhich allows for more open flow in some embodiments.

FIG. 39 is a schematic illustration of the embossed filter media sheetshown in FIG. 1 and accordingly no additional description isnecessitated.

FIG. 40 shows another embodiment wherein at least two different pressstations and presses 28 would be utilized in the machine assembly line10 of FIG. 1, and in series to facilitate stamping of alternatinggrooves into the embossed filter media sheet 282 shown in FIG. 40.Specifically, embossed filter media sheet 282 includes a first set ofembossed panels 284 with schematically indicated embossments defininggrooves 286 that extend longitudinally between creases 288 whichfacilitate pleat folds; and a second set of embossed panels that havetransverse grooves 292 extending in a different direction fromlongitudinal grooves 286 and that may run parallel with the creases. Thelongitudinal grooves 286 run transverse to the creases and preferablyperpendicular to the creases 288 in this embodiment. This providesbridge strength in two dimensions and better ensures and preventsblinding off during fluid filtration.

Turning to FIG. 41, embossed filter media sheet 294 is provided that isthe same as that of FIG. 39, and of the embodiment shown in the machineassembly line 10 of FIG. 1, but in which the trimming operation has beenused to cut from opposed side edges 78, 80 at cut lines 296, 298 usingthe trim knife 76 shown in the machine assembly line 10 of FIG. 1.Trimmed segments 300 are removed from the embossed filter media sheet294. This can be employed to create unique and different shapes. Whilewedge-shaped trimmed segments 300 are shown in FIG. 41 more typically,stepped segments will be conducted whereby the shape of the embossedpanel will match that of the flat panel to create any of the shapes inFIGS. 47, 48, 49, 56, and 57 for example. Two adjacent panels willtypically have the same cut profile (not shown in this embodiment butshown in FIGS. 45-49 for example). Thus, the cut lines 296 and 298 andresulting trim segments 300 can be adjusted or coordinated to thedesired shape of the filter media pack according to the embodimentsshown in FIGS. 47, 48, 49, 56, and 57.

Turning to FIG. 42, a schematic side illustration of a filter media pack302 is illustrated having an upstream flow face 304 and a downstreamflow face 306 for fluid flow. The pleat tips 308 at the downstream face306 are pinched together and may even compress the embossments slightlyto provide for a narrower width at the downstream flow face 306 ascompared to the upstream flow face 304. The upstream flow face mayalternatively or additionally be fanned out such that adjacent panels orsets of embossed panels do not touch each other; whereas at thedownstream flow face, all of the panels are in contact with each other.This may be facilitated by the fact that the grooves and strengthafforded by the filter media allow for this feature to be implementedwithout requiring additional structural support. This may beparticularly advantageous in an air cleaner housing where there may bemore room at an upstream end than a downstream end while being able toallow for increased flow area at the upstream end. Spacers may beinstalled at the upstream end to fan out pleats and maintain spacing..

Turning then to resulting filter media packs that may be achievedthrough trimming attention will now be directed towards the additionalembodiments of FIGS. 45-58, one of ordinary skill will understand thatin each of these embodiments they are structurally the same as theembodiment shown in FIGS. 1, 43, and 46 and also usable in being madewith the press 28 and assembly line 10 of FIG. 1, such that theafore-described features of the prior embodiments are also applicable tothese embodiments and like numbers may be used for greater understandingas done throughout. However, additional features and distinctions willbe discussed.

Turning to FIGS. 45 and 46, curved filter media pack 310, as shown inFIG. 45; and curved filter media pack 312 as shown in FIG. 46, areillustrated and are much the same other than the media pack 310 shown inFIG. 45 has a displacement of 45° between the inlet face and the outletface whereas in the embodiment of FIG. 46 the curved filter media pack312 has a displacement between the inlet face and the outlet face of90°.

Both of these embodiments are made and created with similar methodologyas such attention will be focused upon that the embodiment of FIG. 46understanding that the same description applied to FIG. 46 is alsoapplicable to FIG. 45. In making the filter media pack 312, theembossing features on the respective stamping dies employed in theassembly line of FIG. 1 do not extend linear but extend along a curvedpath to form corresponding curved embossments to define curved ridges314 and curved grooves 316 extending between two flow faces 318, 320wherein one of the flow faces is an inlet face and the other being anoutlet face. At flow face 318, scores 322 are provided which definecreases and folds between emboss plate panels 324 and an unembossed orflat plate panels 326 thereby providing a plurality of pleats which inthis embodiment form a plurality of pocket pleats 328. As can be seen,the flow faces 318, 320 may be flat in the aggregate (i.e. able to lieflat) and similarly two side faces are flat side faces 330, 332 are inthe aggregate flat (the back side face 332 being the back side of thelast flat pleat panel 326 with the front flat side face 330 being theembossed pleat panel 324). In contrast the other two sides are curvedsides 334 and 336 that extend from one flow face 318 to the other flowface 320 and transversely between the flat side faces 330, 332.

Preferably, the shape of the curved ridges, 314 and curved grooves 316match the curvature of the curved sides 334, 336.

To create this filter media pack preferably the trim knife 76 isutilized to cut away regions of each emboss plate panel 324 and flatpleat panel 326 as indicated by dashed cut-away regions 338, 340 thateach indicate the section of each panel that has been cut away to formthe curved shape. Additionally, in order to form pocket pleats, adjacentpairs of embossed and flat pleat panels 324, 326 are seamed together andbonded together through adhesive and/or ultrasonic welding at curvedseam 342, and curved seam 344 to avoid unfiltered air flow through theseseams and to ensure that as fluid travels from one flow face to theother flow face that filtration occurs and no unfiltered air flowtravels through the curved filter media pack 312. Additionally, thecrease at the other flow face 320 is created by an end seam 346 tocomplete the pocket pleats 328 which is also performed by the ultrasonictool (e.g. the plunge welder 84 and anvil 86 as shown in the machineassembly line 10 of FIG. 1) or created via the adhesive applicator inwhich adhesive is applied to join adjacent pairs of individual pleatpanels.

It can be seen with the embodiments shown in FIGS. 45 and 46 that thelength of the grooves can extend between the first end face and thesecond end face with the grooves making a turn of at least 20° and theoverall filter media pack also making a turn of at least 20°. This maybe advantageous in various applications where space is limited or needsto make a turn such as in various engine filtration applications whichallows for flexibility of design to accommodate other engine componentsaround the filter (e.g. such as a pipe or duct).

It will also be appreciated that in this embodiment pocket pleats maynot be necessitated but instead alternatively, the curved sides 334 and336 may alternatively be formed with molded side panels to preventleakage or seal off those side faces similar to as is done in theembodiment of a completed filter media pack with sealing system asindicated in FIG. 36 for example.

Turning to FIGS. 47 and 48, two additional irregular-shaped filter mediapacks 350, 352 are illustrated in which the flow faces arenon-rectangular. For example in the regular filter media pack 350, theflow faces 354 are formed via a cut line 356 by virtue of the trim knife76 employed in the machine assembly line 10 of FIG. 1. This embodimentdoes include a cuboid portion 358 and a non-cuboid portion 360 thattogether make up the overall irregularly-shaped filter media pack 350.It can be seen that the embossments also run transversely and preferablyperpendicularly to the flow faces 354 in this embodiment. In the cuboidportion 358, the trim knife 76 may not be necessitated for use but isnecessitated for use in creating the non-cuboid portion. The outerperipheral sides 162 of media pack 350 which includes some planar facesand the curved portion may be mounted with a suitable frame and adhesiveattachment or can be over-molded if desired to prevent unfiltered airflow when fluid flows between the respective flow faces 354. Theirregularly-shaped filter media pack 352 of FIG. 48 is much similar tothat of FIG. 47 other than the shape being different such that theaforementioned description is applicable to FIG. 48 other than the shapevariation. It is seen in FIG. 48 that a V-shaped filter media pack maybe achieved as an alternative. This emphasizes the flexibility anddesign in that it may take a variety of shapes from cuboid shapes tonon-cuboid shapes and allow for design variation to fit a variety ofdifferent housing configurations.

Turning to FIG. 49, a further embodiment of a filter media pack 166 isillustrated that is quite similar to that of FIG. 43 and as such thesame description thereto is applicable but in this case the trim toolknife 76 of FIG. 1 is used to cut a different shape to make one flowface 168 of a different shape than a second flow face 170 by cutting atleast one side to provide one or more tapered sides.

In this manner, the filter media pack 166 takes the form of atrapezoidal shape. Again the tapered sides may be sealed and over-moldedif desired or pocket pleats can be formed by seaming adjacent pleatpanels if desired.

In the embodiments of FIGS. 50-53 additional media packs 174 and 176 areprovided in which respective flow faces 178 (shown in FIGS. 50 and 51)and flow faces 180 (shown in FIGS. 52 and 53) while planar are notparallel with each other. This can be accomplished by varying the heightof the pleat which is allowed and permitted in that the filter media maybe advanced a predetermined distance as desired. Additionally, ratherthan just simply having one press station, and press 28 as indicated inFIG. 1, a series of presses 28 may be provided, one for each differentlength of embossment provided to facilitate the variable length and spanof the filter media pack and embossments between the respective flowfaces 178 shown for FIGS. 50 and 51 and flow faces 180 shown for FIGS.52 and 53. These filter media packs 174, 176 may also be fitted with anouter frame or wrap structure such as shown in FIG. 36 and facilitatedwith a housing seal as also shown for FIG. 36.

Turning to FIGS. 36 and 37 a perspective and top view of a replaceablefilter cartridge 382 incorporating the pleated filter media pack 16 isillustrated that is usable for a replacement filter to filter air in anengine air filtration application such as being installed in an aircleaner housing (not shown) and sealed against a corresponding sealingsurface of such an air cleaner housing. It is also understood that anyof the filter media packs such as shown in FIGS. 43-58 may also beequipped with the same component with the shape of the side panels andseal configured to fit in surrounding relation for example of suchfilter media pack to the desired shape, such that the teachings anddisclosure pertaining to this embodiment are applicable to the otherembodiments of other shaped filter media packs disclosed herein tocreate filter cartridges that are usable in air cleaner housings and/orthat can be connected to an fluid filtration circuit.

In this embodiment, the filter cartridge 382 employs a cuboid andrectangular filter media pack such as the filter media pack 16 createdfrom assembly and line of the first embodiment of FIG. 1 and asrepresented by the filter media pack 16 in FIG. 1 and FIG. 43(understanding that the media pack 43 would have additional pleats overa lateral span to fill the square shape shown for the media pack 16 inFIG. 36). As shown therein, the filter media pack 16 includes integrallymolded and molded-in-place side panels 384 on first and second oppositesides and that are integrally bonded and imbedded with correspondingside edges 78, 80 of the filter media sheet on opposed sides of thepleated filter media pack 16. It can be seen that these side panels 384cover the full length of the sides between the opposed flow faces toprotect and seal the opposed sides of the media pack where the raw edgesof the emboss plate panels and the flat pleat panels are located. Bysealing it is meant that the flow of unfiltered fluid is not allowed topass through the side edges when installed in an air cleaner housing.

A relatively hard material of polyurethane may be used for the sidepanels 384 to provide for additional support.

Additionally, the fabricated side panels 386 in the form of fiber board,plastic, metal or other rectangular shaped panels may optionally beattached in covering relation to the embossed pleat panels or flat pleatpanels at the other two opposed sides that extend perpendicularly to themolded-in-place side panels 384. The prefabricated side panels 386 areembedded within during the integral molding of side panels 384 toencapsulate these and provide for sealing relationship. Theprefabricated side panels 386 may be attached and sealed along theirentire lateral span with suitable adhesive such as polyurethane toattach and seal the side panels 386 to the opposite sides of the mediapack in a manner that prevents flow of unfiltered air flow from one flowface 198 to the other flow face 200.

Alternatively, panels 386 may also be molded like panels 384 and alsoformed of polyurethane or other molding material.

Additionally, filter media cartridge 36 is provided with a housing seal388 that may be a prefabricated seal that is glued and sealed around theperiphery of side panels 384 and 386 in a manner that preventsunfiltered air flow through the filter cartridge from the inlet face tothe outlet face or that is molded and placed around the outer peripheryof side panels 384 and 386.

For example, housing seal 388 may comprise elastomeric material such aspolyurethane, nitrile, rubber or other such elastomeric material that issuitable for providing either an axial seal or radial seal with ahousing.

In an embodiment, the housing seal 388 is made of a material that issofter and more elastomeric than the harder material of side panels 384and the side panels 386 which may also be formed of elastomericmaterials such as polyurethane.

In another embodiment, the housing seal 388 may be integrally formed atthe same time and/or formed of the same durometer material as the moldedside panels 384.

It is also understood that rather than providing separate side panels384 and 386 that side panels 384 and 386 may instead be a prefabricatedrectangular casing that has a rectangular opening and void for receivingthe filter media pack 16 in which the filter media pack 16 would beadhesively attached and sealed around its periphery to such rectangularprefabricated housing. As such, side panels 384 and 386 may also be forexample a prefabricated plastic or metal or paperboard or cardboardrectangular shell in the form of a casing that takes the same shape asthat of the media pack and receives the media pack therein. Such a shellin the form of a casing may then also provide a structure for supportinga seal or providing for integral molding of a seal thereto to providefor the housing seal 388.

A wide variety of fluted filters, direct flow filters, panel filters andpanel filter casings are known in the art, and the media packs of theembodiments herein can be used to replace those while using the samecasings and sealing systems of those prior systems.

Turning to FIG. 54, another embodiment of a pleated filter media pack390 is provided wherein each of the panels are embossed such as wasshown for example in FIG. 40 but wherein the adjacent panels definedifferent sets of embossments which in this embodiment includes firstskewed embossments 392 extending from an inlet face 396 to an outletface 398 and a second set of skewed embossments 394 that also extendfrom an inlet face to an outlet face. However the first and second setsof skewed embossments extend at different angles as can be seen. Itshould be noted that the embodiment of FIG. 54 is viewed from a side ofthe filter media pack 390 such that the first set of skewed embossments392 are shown on the side face of the structure and the second set ofskewed embossments 394 are on the very next panel behind and thereforeshown in dashed lines. With this arrangement, each panel may be embossedand this also provides for additional structural support in thatembossments are extending in two different directions and further eachpanel is embossed to provide structural support. Further, an advantageof this design is that the angles provide different dimensions ofstructural support not realized when embossments only extend in onedirection. It will be understood that the pleated filter media pack 390shown in FIG. 54 may be of a cuboid shape and therefore also used oremployed in a similar manner such as pleated filter media pack shown forexample in FIG. 1 or 43 for example.

Turning to FIG. 55, another embodiment of a filter media pack isillustrated and that can be created using the filter media pack 16 shownin FIG. 1 but wherein individual panels are shifted to create a curvedpleated filter media pack wherein the front pleat panel 402 is shiftedfrom intermediate panels and the back pleat panel 404 to provide opposedmatching curved sides 406 that are formed via the side edges 78, 80 ofthe filter media sheet. As a result, two of the sides extending betweenflow faces 408 are the curved sides 406 shown and two of the sides areflat sides provided by the front pleat panel 402 and back pleat panel404 in that these will generally lie flat along a surface even ifembossed. When in use, and jacketed or employed in a housing shelland/or molded panels carrying a seal, flow will flow between the flowfaces 408 to filter fluid flowing therebetween.

Turning to FIG. 56, a pleated filter media pack 410 is illustrated thatis the same as that coming off the line for pack 16 except that anirregular corner portion 412 has been trimmed away via the trim knife 76option of the line assembly of FIG. 1 to disrupt the otherwise cuboidshape of the media pack 410 in this embodiment. Removal of the cornerportion 412 provides for a void that can receive for example a pipe,duct, engine assembly or other component and may allow for the filterhousing in which it is installed to also include or accommodate such ashape that may allow for other engine components to protrude up intowhat would otherwise be a rectangular cuboid filter housing. This way,space which is limited under the hood in many engine applications can beaccommodated by allowing for components to project up into areas thatwere not possible due to the previous cuboid or cylindrical shape of anair filter housing. In this embodiment, one flow face 414 is rectangularwhile the other flow face 416 is irregular. The irregular flow face 416can be made and accomplished via the welding and anvil tool which joinsand seams adjacent pleats providing for pocket-like pleats to finish upand seam the pleat edges and creases along the irregular flow face 416as described above for other embodiments.

FIG. 57 illustrates a circular pleated filter media pack having circularupstream and downstream flow faces 420. A circular shape also allows fordeep pleat technology to be used in circular pleated filter packs wherea substantial amount of filter media is constrained within the volume ofthe filter media pack 418 as shown in FIG. 57. This media pack is alsoformed according to the similar methodologies as described above forexample in relation to FIGS. 47 and 48 and otherwise where discussed inthis application with trimming of the panels to the width shown in FIG.57. The description for those embodiments is also applicable to FIG. 57.It can be seen in this embodiment that each set of pleat panels arevariable and span across a lateral distance extending perpendicular tothe flow direction through flow faces 420 as variable width panels 422extend from a front side 424 to a back side 426.

As in many of the embodiments, the flow through the flow faces isgenerally transverse and typically or preferably perpendicular to theflow faces and thus is a straight through flow or direct flow throughwhich in this case in the pleated filter media pack 418 of FIG. 57 islongitudinally or along the axis that cuts through the circular flowfaces the axis being directed through the centers of the flow faces.

FIG. 59 illustrates a slanted pleated filter media pack 428 whereinslanted embossed panels 430 and slanted flat panels 432 extend atoblique angles relative to the plane of the flow faces 434. This can becreated through appropriate creases and the folding techniques at thepleat tips 436 by providing an additional angle or bend 438 asindicated.

Also as with the other embodiments, flow through the filter media packbetween flow faces 434 is from one flow face towards the other flow facewith the air flow having to pass through the filter media sheet suchthat unfiltered air flow between the flow basis 434 is not permitted.This may also be employed and used very similar to cuboid shapes butalso allows for design variation for a variety of reasons.

FIG. 58 illustrates yet another curve in this case corkscrew pleatedfilter media pack 440 that is accomplished by shifting individual pairsof embossed and flat panel pairs 442 relative to each other. Forexample, adjacent sets of pleat panels or pleat panel pairs 442 areshifted relative to each other such that at least two of the filtersides are non-planar and in this case all four sides 444 are curvedsides to form the overall corkscrew shape. Only the sides defined by thepleat panel pairs 442 are flat in this embodiment. It should be notedthat two of the sides (e.g. the sides where the scores and pleat foldsare located) form flow faces 446 with one being an inlet flow face andthe other being an outlet flow face.

Turning to FIG. 60, it is seen that there is another embodiment of apleated filter media pack 448 shown in FIG. 60 but wherein only two ofthe panels 450 are shown and also separated from one another forillustrative purposes. However it will be understood that additionalpleat panels similar to those of panels 450 would be joined at the freeends integrally via a continuous sheet and compacted together like theother embodiments.

In this embodiment, each pleat panel 450 includes embossments includinga first set of embossments 452 and second embossments 454 that togetherprovide for an overall embossment feature that extends a full lengthbetween flow face 456 and flow face 458 wherein one of the flow faces isan inlet face and the other is an outlet face. The flow faces may bedefined and provided by pleat tips 460, 462 as is the case with theother embodiments as well.

Additionally, it can be seen that the first embossments 452 differ fromthe second embossments 454 to provide for additional support, filtrationor other functional features. In this case, the first embossments 452extend from a first plane of the panel into an upstream face of thefirst panel and the second embossments 454 extend into a downstream faceof the first panel 450. In other words, the first and second embossments452, 454 project from opposite sides of the filter media sheet in thisembodiment which provides an overall thicker embossed structure to theoverall sheet. The embossments generally extend between the opposedpleat tips 460, 462 at the opposed flow faces 456, 458. This may also beused to form a cuboid and rectangular filter media pack such as thefilter media pack 16 shown for example in FIG. 1 and FIG. 43 but mayalso be used for other embodiments as well.

FIG. 61 shows a pleated filter media pack 464 much like that of FIG. 60such that it will be understood that filter media pack 464 of FIG. 61 isstructurally the same as the embodiment of FIG. 60 such that theabove-described features for that of FIG. 60 including how it isillustrated are applicable to this embodiment. However additionalfeatures and distinctions will be discussed. In this embodiment, thefirst set of embossments 466 and second set of embossments 468 thatproject from different sides of each pleat panel extend only a partiallength between opposed pleat tips or flow faces 472, 474 for example,the embossments 466, 468 on panel 470 are adjacent to the upstream pleattips and flow face 472 and spaced via a gap from the pleat tip definedby the other flow face 474.

The other pleat panel joined to pleat panel 470 at the pleat tip shownat flow face 476 (and also would be joined at pleat tips that would beat flow face 472) include first and second sets of embossments 478, 480that project from opposite sides of the plane of the filter media sheet.In the aggregate, the embossments 478, 480 in conjunction with theembossments 466, 468 provide an overall embossment structure thatextends a full length of the filter media sheet between flow faces 472and 474 to provide for bridge strength through a central region of thefilter media pack 464. Embossments 466, 468 and embossments 478, 480overlap with each other (that is they are at least adjacent to eachother or that extend past each other in the middle region sufficient toprovide for bridge strength) in the middle region.

Turning next to FIG. 62-66, optional tab features are shown that may beintegrally formed with the filter media sheet or separately attached tothe filter media sheet and usable in any of the embodiments of filtermedia packs disclosed herein. As such the afore-described features ofprior embodiments are also applicable to these embodiments. Howeveradditional features and components used in these embodiments will bedescribed and discussed that are usable with the other embodimentsdiscussed herein.

FIG. 62 shows a filter media pack structurally the same as filter mediapack 16 shown for example in FIGS. 1 and 43 but for illustrativepurposes only two of the pleat panels are shown and further, the pleatpanels are separated and pivoted away from each other for illustrativepurposes to better convey concepts to the reader.

In this embodiment, two separate tab structures are provided, althoughembodiments may include none or only one of the tabs.

One type of tab are the seal support tabs 482 that are bonded viamechanical or adhesive, pressing or other bonding attachment to flatpleat panels 472. Support tabs 482 project outwardly from opposed sideedges 80, 78 of the filter media sheet to support a housing seal 484that would extend in a continuous annular loop much like the annularrectangular housing seal shown for FIG. 36 for example. The housing seal484 is integrally bonded to both the seal support tabs 482 as well asintegrally bonded preferably to both the embossed pleat panels 70 andflat pleat panels in the finished media pack (recalling that the panelsare pivoted away and separated only for illustrative purposes in FIG.62). The seal support tabs include a first attachment portion 486 bondedto one of the pleat panels (in this case the flat pleat panel 80); and aseal support portion 488.

The seal support portion 488 may include irregularities and not beplanar to have seal bonding enhancement to prevent seal delamination.

For example, the seal support portion 488 may include holes throughwhich the seal material of the housing seal 484 flows during formation.For example the housing seal may be molded from polyurethane that flowsthrough the holes 490.

During formation of the housing seal 484 and when the seal material isyet uncured, and in a fluid state, the seal support portion 488 of theseal support tabs are embedded in the seal material of housing seal 484as well as portions of the opposed side edges 78, 80 of the sheet andacross the first and last end panels of the pack whether they be flatpanels or embossed panels to complete and form an annular surroundingperiphery of the pleated filter media pack.

It is preferred that the seal support tabs 482 are formed of a morerigid material than that of the filter media sheet 12 to provide foradditional seal support and attachment. For example the tabs maycomprise plastic, paperboard, or metal material.

While only one flat panel 72 is illustrated it will be understood thatthe various flat panels or alternating flat panels if desired and alsoif desired embossed panels 70 may also include and have the seal supporttabs 482 attached thereto. Such that a variety of seal support tabs mayextend in an array around the rectangular periphery of the media pack.

Additionally, a second type of tab is provided in the form of pleatsupport tabs 492 that include a first wing 494 and a second wing 496connected by hinge 498. It can be seen that the hinge is positioned overthe pleat tip 500 and serves to fasten and provide for additionalsupport at the pleat tip regions where the embossments merge or diminishin size as they merge into the pleat tip. The wings 494, 496 are pivotalabout the hinge 498 and are cinched and fastened together by a suitablefastener such as rivet 502 that may be pressed and snap-fitted into ahole 504 (or in alternative to snap fit, the other end of the rivetdeformed to provide an enlarged head once pressed through hole 504).

It will be understood that in a finished pleated filter media pack, thepleat tip 500 and fold will be completed such that the correspondingflat pleat panel 72 and embossed pleat panel 70 will extend parallelwith each other in the context of a filter made according to thisarrangement and as such the wings 494 and 496 will also extend parallelto each other when the rivet 502 is snap-fitted or otherwise securedwithin hole 504.

It will also be understood that the pleat tips 500 at both upstream anddownstream flow faces may be cinched together with pleat support tabs492 even though FIG. 62 shows that the pleat support tabs only at one ofthe pleat tips and flow faces provided thereby. Further, at either orboth flow faces, all of the pleat tips 500 may be fitted and cinchedwith pleat support tabs 492 or alternatively alternating or selectedpleat tips 500 may be fitted with pleat support tabs depending uponwhere additional cinching and support is desired.

Turning to FIGS. 65 and 66, the filter media package 16 is additionallyshown to include a trimmed edge that may be along one or both side edges78, 80 that defines an integral tab 506 formed into the filter mediasheet 12. Thus, the tab 506 is formed of the filter media. The integraltab 506 is another form of a seal support tab but in this case it isintegrally formed and projects outward from a remainder of the side edge78 and/or 80. By projecting outward, the integral tab can more readilybe embedded within a molded housing seal 508 during the formation ofhousing seal 508 prior to curing of the housing seal and when it isstill in a fluid state. Again the housing seal 508 would also extendaround a periphery of the completed filter media pack much like thehousing seal shown for FIG. 36 for example. Housing seal 508 may notextend in a diagonal or skew relative to the inlet and outlet flow facebut may extend in the same plane as the inlet and outlet face asillustrated in this embodiment and as such for the embodiment shown inFIG. 64.

In FIG. 67, the filter media pack may be the same filter media pack 16as shown in prior embodiments but additionally includes pressed thereina graphic and brand 510 that provides at least one of brandidentification (e.g. trademark), an indication of flow direction, andinstallation information filter media parameters, and/or part numbers.This may convey important information to the mechanic, customer or otheruser of the filter media pack 16. This may be imparted simply on one ofthe exposed end panels or may be conducted throughout the filter mediasheet. When it is done on the end panels it may be conducted by aseparate press plate that may be interchanged during manufacture withthe embossed press plate at press 28 or employed in a separate pressstation similar to press 28 positioned downstream of the press and inseries with the press shown in FIG. 1. The brand may take the form of anembossment or may also take the form of flattening of a previouslyformed embossment but this is advantageously formed via pressingoperation.

It will be appreciated that such information such as the branding andsome of the other embossment features shown herein may not readily beformed via circular rolls.

Further, press plates being planar are much less expensive thanembossing rolls and thus using press plates provides for additionaladvantages over using rolls in embodiments. Many different press platesof different shapes sizes and configurations can inexpensively be madeand interchangeably used in the various press assemblies and lineembodiments discussed herein.

In the FIG. 67 embodiment, it is shown that the brand 510 also takes theform of an embossment but again it is noted that it may simply bestamped flat and flatten the embossments previously formed rather thanbeing an embossment. Thus this provides another type of feature inaddition to embossments and score lines that may be pressed into thefilter media pack using stamping dies. The brand forms a type of graphicthat can readily be understood and convey useful information to an enduser, customer or other interested party.

FIGS. 68-79 are illustrated to show different types of embossments andthat not all embossments need to be uniform or identical and furtherthat embossments may nest within each other. Any of these embossmentstructures may be employed and formed into the stamping emboss platesand into the corresponding filter media sheets in the variousembodiments of filter media packs and embossed sheets disclosed herein.Further, these images show close-up images of the embossments to showthat the embossments may define a projection on one side of the filtermedia sheet and thereby on the other side of the filter media sheet agroove. Various patterns are shown to include saw tooth pattern, offsetpatterns, symmetrical patterns, and nesting patterns as well asdifferent heights, widths and configurations. Additionally, theembossments also may define and provide grooves between adjacentembossments.

As used herein, the term embossment is meant to be broad to generallyinclude a structure that stands out in relief. Preferably the embossmentwill include and provide for grooves as discussed herein in the case ofa filter media sheet which typically has a predetermined caliperthickness.

Turning to FIGS. 80-85, different configurations of embossments arepossible with curved embossments 512 and linear embossments formed inthe various different embodiments of pressed pleat panels shown forFIGS. 80-85. It will be understood that these embossed pleat panels ofFIGS. 80-85 are usable in any of the filter media pack embodiments andsome of them such as FIGS. 80 and 81 are particularly useful inassociation with pocket pleats to direct flow through an outlet facethat extends not only over the plate tip but also along the side edgesor seams of bonded adjacent side edges of individual pleat panels. Thus,the afore-described features of the prior embodiments are applicable tothese embodiments and additional features and distinctions will bediscussed with the understanding that these embossed panels may be usedor substituted for the embossed panels of the filter media sheetemployed in the other filter media packs.

In FIG. 80, the curved embossments 512 project from the pleat tip 516 atthe inlet flow face and includes linear embossments 514 in the middleregion. The curved embossments 512 that extend away from the linearembossments 514 as the curved embossments 512 extend from the pleat tip516 at the inlet flow face towards the outlet flow face (or vice versafrom the outlet flow face to the inlet flow face). This is particularlyadvantageous when using pocket pleats when air is permitted to flow notonly axially through the media pack but also laterally through the mediapack in the direction of the curves.

In each of these embodiments, dashed lines are used to indicate thatembossments being curved embossments 512 or linear embossments 514 canproject not only from one side of the plane of the filter media sheetbut also from the other side of the filter media sheet. Additionally oralternatively the dashed lines may also be understood in anotherembodiment to be a separate embossed sheet immediately behind the frontembossed sheet in which the curved embossments of the two sheets nestwith each other (project in gap regions between embossments) and thelinear embossments nest with each other which can be the case as wasshown for example in FIG. 79.

Turning to FIG. 86, an alternative embodiment of a machine assembly line520 is illustrated. It will be understood that the machine assembly line520 is structurally the same as the machine assembly line 10 of thefirst embodiment shown in FIG. 1 such that the afore-described featuresof the prior embodiments discussed in association of FIG. 1 are alsoapplicable to this embodiment including the optional features used forthat embodiment. It will also be understood that this machine assemblyline 520 may be used to form the various embodiments of pleated filtermedia packs of the various filter media packs described herein and isusable for that purpose. As such, additional features and distinctionswill be discussed and it is also understood that in this embodimentmultiple presses are provided that may be used to provide for differenttypes of embossments including two different types of embossed panels ifdesired.

In this embodiment the filter media roll 14 and its filter media sheet12 along with optional laminate sheet 88 coming from optional laminateroll 90 are driven in a travel pack 522 from an upstream region to aplate collector in the form of pleater 524 which is schematicallyillustrated. In this machine assembly line 520 the filter media sheet 12may be continuously driven along the travel path by advance rolls 526and not stop intermittently or stop at all during processing, that isuntil filter roll 14 is exhausted and stoppage is necessitated forchange-out or break-down. This is accomplished by an endless loop 528 ofa plurality of presses 530 that are rotated along the endless path ofthe loop 528. The presses 530 may be similar to the press 28 asdescribed in conjunction with FIG. 1 including all of its componentsincluding the ram, upper stamping die, lower stamping die and controlsbut in this instance the presses 530 are driven in the endless loop inthe direction indicated in FIG. 86 and at the same speed as the filtermedia sheet along the travel path such that intermittent stoppage is notnecessary. However this may also be used with intermittent stoppage ifdesired to allow for dwell time and may alternatively provide for theadvantages of pressing different types of embossments into differentpanels as may be desired.

It is noted that part of the loop 528 that extends over the travel path522 when the presses 530 are engaged in actively pressing the media islinear and travels parallel and at the same speed as travel path 522.Further, while the presses 530 are disengaged in traveling around thecurvature of the loop, they may be disengaged and heated. Inactivepresses along the loop may also have plates switched out to providebranding or other lengths of embossments or other features.

Additionally, the media advance conveying mechanism in this embodimentmay be the presses itself and it may not be necessary to have theadvance rolls 526 in that the presses and being driven in the endlessloop and in engagement with the filter media sheet itself can drive andconvey the filter media sheet along the travel path.

Optionally, adhesive applicators to apply adhesive such as hot melt maybe used and further, a trim knife such as a water jet, laser, shearknife or cross-cut knife or other such knife may be used to cut andshape and slit the media as may be desired. This may be done on acontinuous basis.

Optionally, the tooling plates of the presses 422 are heated and havemultiple heat zones and may be also heated while disengaged from thefilter media sheet.

Turning to FIG. 87, yet a further embodiment of a continuous process diepress pleater and machine assembly line 540 is illustrated where it isunderstood that it is structurally the same and includes presses and itscorresponding features as in the first embodiment shown in FIG. 1 andalso able to form the various filter media packs of the variousembodiments disclosed herein. However additional features anddistinctions will be discussed with reference to this embodiment. Inthis embodiment the machine assembly line 540 includes a table havinglinear slides 544 that facilitate linear reciprocating movement of twoindexable pleat press carriages 546, 548 (each of which may include oneor more pleat presses if desired in series).

The filter media roll 14 and its filter media sheet are driven along atravel path 552 that is linear and extends toward a pleat collector inform of pleater 550 that is schematically indicated at the downstreamend with the pleat press carriages 546 and 548 therebetween. It will beunderstood that each pleat press carriage incorporates and carries apress that is similar to press 28 as described in the first embodimentto include the upper and lower stamping dies and the electronicallycontrolled ram. However in this embodiment, the pleat press carriagesreciprocate along a linear path on the linear slides forward andbackward parallel to the travel path 552. In this instance, pleat presscarriage and its press are actively engaging and pressing the filtermedia and thereby engaged with the filter media sheet as it is beingtravelled along the travel path. The pleat press carriage 546 is movedat the same speed as the filter media sheet 12 along the travel path552. Additionally, it will be understood that pleat press carriage 546may not just include one set of emboss and score plates but perhaps aseries of several presses and corresponding upper and lower embossplates along the line to press several pleat panel sections at the sametime or in sequence.

While the press carriage 546 is engaged and actively pressing andadvancing the media, the pleat press carriage 548 is disengaged andtraveling in a reverse direction to be at a point where it can startpressing panels immediately behind the engaged pleat press carriage 546that is traveling forward with the media sheet. Once the pleat presscarriage 546 completes its pressing, it will disengage and also thentravel backwards while at the same time or about the same time the pleatpress carriage 548 that is disengaged will become engaged and start topress and then move along the travel path 552, at the same speed as theadvancement of filter media sheet 12. In this embodiment, the presscarriages themselves when engaged may drive the filter media sheet alongthe endless path and may do so in a continuous non-intermittent fashionthereby increasing production in capacity. This also may be outfittedwith the various optional features of the prior embodiments discussedthe machine assembly lines 10 or 520.

Yet a further embodiment of a machine assembly line 560 is illustratedin FIG. 88 which is structurally the same as the embodiment shown inFIG. 1 and may include also the features desired in FIG. 1 such that theafore-described features of the embodiments associated with FIG. 1 areapplicable to this embodiment. Further, this machine assembly line 560is also usable in producing the filter media packs according to thevarious embodiments discussed herein.

In this embodiment the filter media sheet 12 coming off filter mediaroll is pressed by a different form of press having lobed nip pressesthat are driven vertically into and out of engagement via a ram providedby hydraulic or electrical linear actuators 564. The lobe nip pressesinclude stamping dies that have at least one planar section 566 and thusare an emboss plate, and may have rounded edges or lobed sections 568the lobed nip rollers may be driven by the linear actuators 564 to notonly facilitate linear pressing but additionally, rotary actuators 570may rotate the lobe nip presses 562 when not in a dwell press mode toadvance the media and score the media in the radius lobed sections 568that can define scoring features along the lobes. It is noted that ineach stamping die the planar section may be embossed both above andbelow such that as it rotates the other press emboss plate is used onthe other side of the stamping die.

FIG. 89 illustrates a progressive stamping die arrangement 574 that maybe used in any of the presses of the embodiments described herein suchas used in machine line assemblies 10, 520, 540, and 560 for example. Assuch it will be understood that the description and disclosurepertaining to those embodiments are also applicable to the progressivestamping die arrangement 574 of this additional embodiment such thatdistinctions and additional features will be discussed.

In the progressive stamping die arrangement 574, the embossment features576 are spread out among a plurality of progressive stamping dies 578that extend transverse to the flow path of the filter media sheet alongits travel path (see e.g. side edges 78, 80 of the filter media sheet12). It is noted that in some embodiments, especially where theembossments are deep that stretching of the filter media sheet and thefibers may be realized to provide for increased air flow permeabilityhowever, if stretching is not desired and deep embossments are at thesame time desired then the progressive stamping die may be used as ittends to gather and move in the filter media sheet progressively ratherthan stretching and may also be used to compress instead in anembodiment. Specifically, a first set of central stamping dies 580 arefirst driven into engagement which gather the filter media sheet andmove outer portions 582 inward thus moving the opposed side edges 78, 80inward slightly as the embossments and the corresponding groove featuresare being formed into the filter media sheet. After the central stampingdie 580 is engaged the next outside guard stamping dies 584 are engagedwhich tend to draw and pull the outer portions 582 and the correspondingside edges 78, 80 inward even further again with little or no stretchingand then the outermost stamping dies 586 are subsequently engaged tofinish off formation of the embossments in the filter media sheet.

With the sequential engagement of the progressive stamping dies from thecentral stamping die outward to the guard stamping dies 584 then theoutermost stamping dies 586 a progressive stamping of the filter mediasheet is accomplished that does not necessarily have to stretch thefilter media sheet and that may also be used to compress the filtermedia sheet if desired to reduce air flow permeability and/or increaseefficiency of the filter media sheet.

Turning to FIGS. 97 and 98, an additional embodiment or features for thepleated filter media packs 16 are illustrated that may be optionallyused with the filter media pack 16. Specifically, these featuresdiscussed below may be used in the filter media packs of any of theembodiments of filter media packs discussed herein and may beaccomplished by welding (such as via ultrasonic welding or other meltingof media together) and/or by way of dispensing adhesive beads and/orpressing. In particular, these features may be accomplished by way ofthe plunge welder 84 and anvil 86 discussed in association with FIG. 1,other welding apparatus or by way of the adhesive applicator 82 whichmay dispense adhesive dots, lines at select locations on the filtermedia sheet.

As shown the filter media pack 16 is shown to include point bonds 100which may be at the pleat tips as shown in FIG. 97 as well as atintermittent locations between pleat tips as shown additionally in FIG.98. Again these may be ultrasonic welds or alternative placement ofadhesive bead dots that may optionally be pressed together. Thisprovides for additional structural integrity and at the pleat tips maycinch the pleats together to provide a wider mouth to allow foradditional air flow through the flow face defined by the pleat tips suchas shown in FIG. 97.

Additionally, this embodiment shows that embossed pleat panel 70 may beseamed to adjacent flat pleat panels 72 in pairs to form pocket pleats604 with three pocket pleats being illustrated in the embodiment of FIG.97. In this embodiment in addition to being able to flow through theflow face defined by pleat scores 68, and thus flow in a direct manner,the air flow may additionally flow sideways or laterally out between theopen regions 606 defined between adjacent pocket pleats 604. The seams602 may also be formed either through adhesive application by formingand laying a continuous bead and then pressing the adjacent pleat panelstogether when forming the pocket pleats and pleating or byultrasonically welding. It is also understood that while only one sideis shown in FIG. 97 for side edge 78 that it is also applicable and thatthe same seam 602 would also be formed on the other side or side edge 80(not shown in FIG. 97 but understood from other figures).

It is additionally noted that the point bonds 600 will also prevent andlimit relative movement between adjacent pleat panels to provide forstructural support and prevent collapsing or blinding off of the filtermedia sheet when subjected to an application where substantial air flowis run through from the inlet face to the outlet face.

While not being limited thereto, certain examples and performance aredescribed below. While the press can be used to process a variety ofconventional filter medias that may include polymers, glass and/orcellulose as described above and thereby provide corresponding mediapacks with embossments and each can have advantages over conventionalpleat packs, certain performance advantages can be obtained by use ofmedias that include polymer materials with the press. For examples,polypropylene media grade A2 and polyester media grade LFP 2.0 have beenfound to have sufficient to excellent processability with the press ofFIGS. 2-13. The selected medias were chosen based on how well they wereprocessed and how well they performs in system level lab tests. Thesemedias may be commercially available melt blown medias from IREMA-FilterGmbH and sold under the IREMA brand, having an business address at Ander Heide 16, D-92353 Postbauer-Pavelsbach, Germany. The characteristicsof these medias are as follows in the TABLE 1 below, but it iscontemplated that similar medias or variations of these grades willperform similarly. Additional high performance medias include Irema LFP2.3 (polyester), Irema LFP10 (Polyester) available from Irema as notedabove, and Grade 30)(zPN/DG7513 (Glass/Polypropylene) which is availablefrom Transweb, LLC of Vineland, N.J. that may be useable in embodiments.

TABLE 1 flat and embossed sheet parameters Irema A2 Irema LFP 2.0Material Polypropylene Polyester Mold/Press Temperature (of 240 335press plates in FIGS. 2-13 in degrees Fahrenheit) Press Time 5 seconds 5seconds Flat Sheet Basis Weight 202 211 (gsm) Embossed Basis Weight 171210 (gsm) Stiffness Flat (mgs) 264.1 197.38 Stiffness Embossed (mgs)954.6 654.9 Mean Flow Pore (μ) 13.7 10.6 Largest Detected Pore (μ) 41.831.4 Mean Flow Pore - 13.2 14.0 Embossed (μ) Largest Detected Pore -52.8 43.6 Embossed (μ) Permeability Flat (cfm) 58.26 36.5 PermeabilityEmbossed 140.20 96.43 (cfm) Embossment Height 85% 93% RetentionEfficiency Flat 0.3-1.0μ % 98.66 92.30 1.0-3.0μ % 99.69 96.24 3.0-10.0μ% 99.98 99.51 Efficiency Embossed 0.3-1.0μ % 95.00 68.93 1.0-3.0μ %97.53 76.29 3.0-10.0μ % 99.22 92.83 Dust Holding Capacity Flat 0.8650.8145 (g/100 cm² @1000 Pa) Dust Holding Capacity 1.637 1.824 Embossed(g/100 cm2 @1000 Pa)

Using these medias and embossing as described above using the embodimentof FIGS. 2-13 and as described in Table 1 (with the plates having anemboss groove depth of 0.18 inch and an emboss groove width of about 0.3inch for the A2 example, and an emboss groove depth of 0.125 inch and anemboss groove width of 0.165 inch for the LFP2.0 example), standardcuboid shaped pleated filter media packs (e.g. shaped like as shown inFIGS. 43, or FIGS. 36,37 or FIG. 1) were created having a height of 7.5inches, a width of 7.5 inches, and a length of 8.2 inches (volume of 461cubic inches). These media packs were compared to a commerciallyavailable Donaldson® Brand G2 fluted filter media pack having a heightof 7.9 inches, a width of 7.5 inches, and a length of 8.2 inches (volumeof 487 cubic inches and designated as comparative “C1” example in Table2 below). The following performance characteristics of these examplesare detailed in Table 2 below.

TABLE 2 Cuboid Filter Media Pack Performance C1 A2 LFP10 LFP2.0 FilterMedia Sheet Area (inch²) 12053 5299 5299 5332 Challenge Flow Rate (SCFM)500 500 500 500 Initial Pressure Drop (PSID) 5.4 5.5 5.2 5.75 InitialEfficiency (%) 99.63 99.9 99.05 99.6 Accumulative Efficiency (%) 99.9799.96 99.87 99.95 Dust Holding Capacity (g) 1528 1359 1128 1583 Grams ofdust/inch² of media .13 .26 .21 .30 Volumetric Dust Holding 3.1 2.9 2.43.4 Capacity (g/inch³)

A substantial performance advantage above can be seen in thatsubstantially less filtration media sheet in terms of area isnecessitated while achieving a similar efficiency, restriction and dustholding capacity and performance. As such, substantially less filtermedia sheet may be required in some embodiments to achieve similarresults and greater dust holding per square inch of media sheet wasobtained. For example, the above demonstrates that filter media packscan be formed having an initial efficiency of at least 99%, and a dustholding capability of at least 0.15 grams of dust/inch² of media, moretypically at least 0.2 grams of dust/inch² of media and in someembodiments at least 0.25 grams of dust/inch² of media.

For the flat and embossed sheets tests above as in Table 1 (and for anypatent claims appended hereto that recite an efficiency and/or dustholding capacity for sheet performance), the testing was and can beconducted with a Palas MFP 3000 test stand with the following conditionsin Table 3:

Table 3

filter area: 100.000 cm²face velocity: 5.8 cm/sdust mass concentration: 150.0 mg/m³dust/aerosol: SAE fine A2total volume flow: 35.0 l/minDust load termination at 1000 Pa increase.

For the filter pack volumetric performance testing such as the cuboidfilter media pack performance and tests for Table 2 above (and for anypatent claims appended hereto that recite an efficiency and/or dustholding capacity for pack performance), the testing is pursuant to ISO5011:2014 (i.e. the ISO test standard for Inlet air cleaning equipmentfor internal combustion engines and compressors—Performance testing),utilizing ISO fine test dust, at an air flow of 500 CFM, and dustload/test termination at a pressure drop or restriction of 30 inches ofwater.

Additionally, while the above embodiments are described as useful withadvantages for pleated filter media packs, it will be understood thatthe press and methods disclosed herein may be used with other types ofmedia packs beside pleated such stacked fluted media panels as thosedescribed in the background section (e.g. such as in U.S. Pub. No.2014/0260139 entitled Rectangular Stacked Fluted Filter Cartridge toMerritt) and as such certain broader claims (for example claims that donot explicitly require pleats or pleated) that are appended hereto aremeant to encompass such possibilities.

Additionally, another embodiment of filter 700 is illustrated in FIG. 99in the form of an irregular shape to define a brand that provides atleast one of brand identification, flow direction, installationinformation, filter media parameters, and part number. The filter 700comprises a filter media pack 702 with an inlet face 704 and an outletface generally indicate in the area of 706 (although the flow faces maybe reversed with the inlet the outlet and the outlet the inlet as inother embodiments). The filter media pack is also preferably of theirregular shape to define a brand that provides at least one of brandidentification, flow direction, installation information, filter mediaparameters, and part number.

Preferably, the filter 700 further comprises a frame 708 over the filtermedia pack 702 and supporting the filter media pack 720, the frameincluding alphanumeric letter characters to form said brand, which inthis case spells the brand name CLARCOR as seen in FIG. 99.

The frame 708 may take the form of and thereby include a grate 707forming the alphanumeric letter characters, with the grate 707 over oneof the inlet face 704 or outlet face 706 of the filter media pack.

Preferably, the frame 708 also includes a surrounding sidewall 703projecting from the grate 707 toward the outlet face or inlet face insurrounding relation of the filter media pack.

Typically, the filter media pack will comprise a plurality of filtermedia panels 711 having a depth projecting between the inlet face andthe outlet face. The filter media panels 711 also have a width extendingbetween opposed sides (see sides 710) of the filter. As can bet seen,the filter width between opposed sides 710 is variable and not constant.Further, the filter media panels 711 are in an array (one panel disposedover the next panel in a linear array in this instance) between opposedends 712 of the filter. It is seen that the opposed sides 710 extendtransversely and preferably perpendicularly between ends 712. Toaccommodate the shape variance of the branding, the filter media panels711 have different widths between opposed sides to form at least part ofa shape of the brand.

Additionally, it also may be that as shown that the adjacent the firstand second ends 712, the filter media panels 711 are of different widthssuch that a span of the filter between opposed ends 712 varies as theends 712 project from a first of the opposed sides 710 to a second ofthe opposed sides 710.

As is the case in earlier embodiments, the filter media panels 711 arepleated and form a pleated filter media pack with trimmed edges form thedifferent widths between opposed sides, such as via use of the trimmingtools shown in FIG. 1 or FIG. 86.

Another aspect of this embodiment is that a filter frame providing brandidentification. The frame 708 may be in the form of and may thereforeinclude grate 707 disposed over the filter media pack having voids 715to allow airflow and members 716 around the voids and in the form of atleast one alphanumeric character to provide a brand that provides atleast one of brand identification, flow direction, installationinformation, filter media parameters, and part number.

As per above, the span of the filter media pack is preferably variableand helps form the shape of at least one alphanumeric character.

Also preferably, a plurality of alphanumeric characters are provided(e.g. to spell CLARCOR) and a span of the filter media pack is trimmedto help form the shape of at least 2 of the alphanumeric characters.

Finally, while not shown, it is contemplated that a gasket or sealprojecting from the outline of the frame at the inlet or outlet face maybe provide and extend in cantilever fashion to form a radial or axialseal, or alternative a seal may be provide in surrounding relation ofsidewall 703 and supported thereby to provide for an axial pinch gasketor a radial seal.

B. Additional Disclosure & Embodiments Pertaining to Filter MediaCutting, Welding & Ultrasonic Press Assembly

It is noted that the description above relating to FIGS. 1-99 isdescribed and contained in the Applicant's prior application, PCTApplication Serial No. PCT/US2016/047283, filed on Aug. 17, 2016,entitled “Filter Media Packs, Methods of Making and Filter MediaPresses” (including the benefit applications of U.S. ProvisionalApplication Ser. Nos. 62/206,100 and 62/243,740 filed Aug. 17, 2015 andOct. 20, 2015, respectively), the entire disclosure of all of which areincorporated by reference in its entirety, as the present disclosurepresents additional embodiments, disclosures and concepts relatingthereto.

Attention will therefore now be directed toward further embodimentsdepicted in FIGS. 100-116. Relative to these concepts and embodiments,it should be first noted that these embodiments of FIGS. 100-116 may usethe embossing press 28 as in FIG. 1 and other embodiments to createcreases 810 to be used for creating pleat folds, or may alternativelyuse a rotary pleater tool such as a rotary die for forming creases 810.For example, as shown in FIGS. 100-104, preformed creases 810 may beformed such in the filter media sheet 812 such as by a press or rotarydie. Optionally, a press 828 may be used to additionally formembossments on an embossed pleat panel 870 that can be adjacent a flatpleat panel 872, separated by crease 810. Embossed pleat panel 870 mayalternatively be simply another flat pleat panel like panel 872.

First referring to FIGS. 100-102, the folding and welding of pleatsegments using a sonotrode assembly 814 and an anvil assembly 816 isschematically represented with a progression of a pleat segmentdevelopment in each subsequent figure. In the initial start positionshown in FIG. 100, the leading pleat crease 810 is arranged between thesonotrode assembly 814 and the anvil assembly 816.

Referring to FIG. 101, the advancing member such as the anvil assembly816 will grab and thereby hold the filter media sheet 812 therebyadvancing the filter media sheet 812. In this case the anvil assembly816 operates to grip and hold the filter media sheet 812 duringadvancement, such that it may also be referred to as a pick member. Thispulls the trailing portion of the filter media sheet 812 and pushes theleading portion of the filter media sheet 812 (the leading portion beingthat which comprises the leading adjacent pair of the pleat panels 870,872). As shown in FIGS. 101 and 102, the leading adjacent pair of thepleat panels 870, 872 is assembled by linearly driving the sonotrodeassembly 814 and the anvil assembly 816 together.

Preferably, the sonotrode assembly 814 is stationary and/or otherwiseacts as a stop member to serve as an abutment during this relativemovement between the sonotrode assembly 814 and the anvil assembly 816.As shown schematically, only the anvil assembly 816 may move linearlyduring the advancement of the filter media sheet 812.

Optionally, and if desired, a crease assist device (not shown) such asan air blast device or a reciprocating vertical pin member that may beused to start the upward movement of the crease 810 between thesonotrode and the anvil assemblies 814, 816. However, if the filtermedia sheet 812 is supported on a suitable filter media support such asa table or a conveyor, the filter media only has one way to go duringadvancing movement such that the crease 810 normally moves upward whenthe sonotrode and the anvil assemblies are brought together without anyassist device.

During the advancing movement, the leading adjacent pair of the pleatpanels 870, 872 are pushed upward and collapsed together along thecrease 810 to thereby fold the filter media sheet 812 and create apleated segment 824 as shown in FIG. 102. The anvil and/or sonotrode mayhave weld projections that project therefrom (see e.g. embodiments ofFIG. 106, and FIGS. 116-118 for weld projection examples) that canoptionally facilitate spot welding of the filter media sheet together atweld locations 818. These can be spot welds similar to tack point bonds600 as in FIG. 97 and/or can form pocket pleats by welded seams atopposed edges (e.g. see seam 602 and pocket pleat 604 in FIG. 97 thatcan be welded using this process). Such weld seams 820 to form pocketpleats are shown better for example using a rib projection tool 836 asin FIG. 116. The rib projection tool 836 can weld along opposed sideedges of the pleat panels 870, 872 to form the seam welds. An ultrasonicemitter operating at typically at least 15 kilohertz may be applied toeither or both of the anvil assembly 816 and the sonotrode assembly 814to facilitate welding. Typically, the ultrasonic emitter is transmitteddirectly to the sonotrode assembly 814, which is in close enough contactwith the anvil tooling to create weld locations 818 to transmit thepower through to the anvil tooling when in close proximity to creatingheat that facilitates welding of the sheet together at weld locations.

Once the folded pleat segment is completed and optionally welded, thepleated segment 824 now formed can be overlaid upon the incipientpleated filter media pack 826 being formed until such pleated filtermedia pack is completed. If desired, cutting the trailing sheet may alsobe done ultrasonically by a knife edge tool that can be advanced andretracted on the anvil to perform a cut when the last pleat segment forthe pack is completed. Alternatively, such cuts may be formed by cuttingknife 74 (e.g. as in FIG. 1).

Also, once the pleat segment 824 is completed as shown in FIG. 102, thesonotrode assembly 814 can be retracted and moved away from the anvilassembly 816. During sonotrode retraction, the anvil assembly 816preferably is sufficiently stationary that allows an opening regionabove the incipient pleated filter media pack 826 to form, which thenallows the now formed pleat segment 824 to fall upon and overlay theincipient pleated filter media pack 826. This is also shown in greaterdetail and described below in reference to FIG. 109 and FIG. 113. Meregravity can alone facilitate the overlaying action, or alternatively itmay be sped up with an assist device such as an air blast devicearranged to push the pleat panel segment 824 toward the incipientpleated filter media pack 826.

Additionally, the process and apparatus is conducive to cutting andseaming cut edges such as arcuate cut edges 830 as can be seen withreference to FIGS. 103, 104, and with additional reference to thetooling shown in FIG. 103A. As shown, each panel 870, 872 has beenfurther cut in these embodiments to have cut edges 830 that areextending obliquely relative to the creases 810 for creating anirregular shape to an irregularly shaped pleated filter media pack 832as schematically illustrated in FIGS. 103 and 104 (the weld seams notbeing visible in the schematic illustrations). Cut edges 830 are used toprovide a formed feature in the filter media pack such as a recesscavity 835. To accomplish seaming of cut edges 830, the anvil assembly816 includes a rib projection tool 822 comprising a pair of spaced apartrib projecting elements 823 and 825. Rib projection element 823 islinear only for creating a linear pocket weld seam between one of theopposed side edges 813 of the filter media sheet 812, while ribprojection 825 includes an arcuate feature corresponding to the shape,location and configuration of arcuate cut edges 830 for welding andseaming the cut edges 830 together. In this fashion, pockets are formedin the pleated filter media pack and the seamed cut edges 830 and seamsalong the opposed side edges 813 are bonded and sealed so as to preventunfiltered fluid leakage by the creation of sealed and seamed pocketpleats.

As shown in FIG. 103, the cutting can be conducted separately after theembossing by an emboss press 828 and/or after creasing but before theassembling of the pleat panels 870, 872 together via folding between thesonotrode and anvil assemblies 814, 816. A knife 834 on a gantry, suchas a blade, laser or water jet can perform such cutting of cut edges 830for example. The knife 834 may be drive both laterally between opposedside edges 813 and if desired in the advance direction (e.g. to cutwhile the sheet is intermittently stopped).

As shown in FIG. 104, alternatively, the cutting by knife 834 isconducted separately before the embossing by emboss press 828 and/orbefore creasing but before the assembling of the pleat panels togethervia folding.

In operation, and in an embodiment, the filter media sheet 812 isintermittently and successively advanced and stopped along the travelpath as shown in the embodiments of FIGS. 100-104. While the filtermedia sheet is stopped, various operations can be performed such ascutting with the knife 834 and/or pressing with the emboss press 828 (tocreate embossments and/or creases). While the filter media sheet isadvancing cutting may also occur via the knife 834.

Yet as a further alternative for cutting, and referencing FIG. 116 as anexample, the anvil assembly 816 may be alternatively configured with aprojection tool 836 (e.g. replacing the rib projection tool 822 withtool 836) that has a knife projection 838. For example this embodimentof FIG. 116, includes two linear projection tool elements 840 fortrimming and cutting opposed edges 813 and simultaneously creatingpocket pleats between adjacent pleat panels 870, 872. In this schematicview, the pleat panels 870,872 are shown schematically from above andbeing separated by crease 810, which is fully folded. Each of projectiontool elements 840 may also include a rib projection 842 immediatelyadjacent the knife projection 838. The rib projection 842 welds the cutedge created by the knife projection 838 to seal the cut edges forming aseam to prevent unfiltered fluid flow therethrough in the completedfilter media pack.

As shown in FIG. 116, the rib projection 842 is wider than the knifeprojection 838, and the knife projection projects axially above andoutward from the rib projection 842. The rib projections 842 are alongthe inside. When two tool elements 840 are provided, the rib projections842 are located between the opposed knife projections 838 of therespective tool elements 840. When the sonotrode assembly 814 and theanvil assembly 816 are brought close enough together a smaller gap isformed at the knife projections 838 than at the rib projections 842 asbetween the sonotrode and anvil assemblies 814, 816 with adjacent panels870, 872 of the filter media sheet 812 sandwiched therebetween. As aresult, the sonic vibrating energy to the knife projection 838 resultsin cutting through the filter media sheet 812 to form cut edges 844thereby trimming away trim portions 846 from opposed side edges 813 ofthe media pack. This reduces the width of the panels 870, 872 andresulting pack. Simultaneously, the sonic vibrating energy is alsodirected to the rib projection 842 forming linear seam welds 848 bondingthe panels 870, 872 together to form pocket pleats. Either of the linertool elements 840 could be formed in a shape like the partially curvedrib projection element 825 of FIG. 103A to simultaneous cut the shapeand weld the shape shown in FIGS. 103 and 104, as will be understood.

Now with a more general understanding of various processes and toolingbeing explained above, attention will now be had to an a more detailedembodiment of a welding and assembling apparatus 850 illustrated inFIGS. 105-115. The welding and assembling apparatus 850 of FIGS. 105-115can be used to implement the methods and structures of FIGS. 100-104and/or use the tooling of FIGS. 116-118 and as such like referencenumbers are used. Similarly it is understood that apparatus 850 can beused can be an embodiment used for the anvil 86 and welder 84 shown inFIG. 1, and therefore used at the end of the assembly line 10. As such,it is understood for upstream operations and stations, reference can behad to the description above and FIG. 1. For example, reference can behad to FIG. 1 for upstream stations such as a filter processing stationto process the filter media with features (e.g. optional press 28 inFIG. 1 and/or a rotary die for embossing and/or creasing); and a filtermedia supply station that would include typically an unwind station 22and a filter media roll 14 as shown in FIG. 1 that supplies the filtermedia sheet 12. The filter media sheet is also referred to as referencenumber 812 in FIGS. 100-118.

Downstream of these upstream stations, the apparatus 850 includes anultrasonic press station 852 comprising the anvil assembly 816 and thesonotrode assembly 814. The anvil assembly 816 and the sonotrodeassembly 814 are space apart along a Z-axis 801 that extends in andtypically parallel with the filter media sheet 812 travel direction. Inan embodiment, the Z-axis 801 is horizontal. Additionally, a Y-axis 802and an X-axis 803 are illustrated, each of which extend perpendicular tothe Z-axis, in the illustrated embodiment. The Y-axis 802 may bevertical and extend perpendicular to the X-axis 803 that extendslaterally and transverse to the travel direction of the filter mediasheet 812.

Arranged along the Z-axis 801 is a linear actuator that reciprocates theanvil assembly 816 (and anvil thereof) and the sonotrode assembly 814(and sonotrode thereof) together and apart along a Z-axis 801 as isshown in progressive sequence in FIGS. 106-109. This progressivesequence is also shown from a different perspective in FIGS. 110-113.While only one actuator may be used for relative reciprocating movement(with one of the anvil assembly 816 and the sonotrode assembly 814optionally stationary), more preferably, first and second linearactuators may act independently upon the anvil and sonotrode assemblies,respectively, as discussed below.

For linear actuation, fluid powered actuators such as pneumaticactuators may be used with defined stops at the end of travel movement.Such pneumatic actuators can move the anvil assembly 816 and thesonotrode assembly 814 by acting directly on the anvil and/or sonotrodeassemblies.

For additional control and to provide for incremental positions, servomotors can be used in linear actuators. For example, as shown in FIG.105, for driving the anvil assembly 816, the linear actuator maycomprises a servo motor 854 (or alternatively a stepper motor) thatrotates a screw shaft 856 that with a nut 858 can translate rotationalmovement into linear movement. For linearly driving the sonotrodeassembly 814, a pneumatic fluid powered cylinder 860 is shown, but itmay also be a linear servo motor drive or linear stepper motor drive.

To guide linear movement, a suitable Z-axis linear slide assembly isprovided as discussed below. For support of the linear slide assembly,vertical support columns 862 are provided in horizontally spacedrelation. The support columns 862 accommodate a table 864 that providesa filter media support surface (optionally and alternatively, filtermedia support can be a conveyer as shown in FIG. 1). The support columns862 support the Z-axis linear slide assembly, which comprises linearguides such as slide shafts 866, and linear slides such as slide collarbushings 868. One set of bushings 868 are affixed to an anvil carriage874. The anvil carriage 874 supports and carries the anvil 876 with thecarriage 874 and anvil 876 being collectively part of the overall anvilassembly 816 as shown. Another set of bushings 868 are affixed to asonotrode carriage 878. The sonotrode carriage 878 carries and supportsa sonotrode 880, which comprises high frequency sonic emitters 881 andsonotrode plate 882. The sonotrode carriage 878 and the sonotrode 880are part of the sonotrode assembly 814.

In this fashion, the pneumatic cylinder 860 is operable to drive thesonotrode carriage 878 back and forth in the Z-Axis 801 between extendedand retracted positions (e.g. see sonotrode positions shown in FIGS. 108and 109). Similarly, the servo motor 854 linearly drives the anvilcarriage 874 and thereby the anvil 876 between extended and retractedpositions (see anvil positions in FIGS. 106, 108, and intermediateposition in FIG. 107). In operation, the servo motor 854 rotates a screwshaft 856 in one rotational direction or the other. The screw shaft 856acts on the nut 858, which is secured to the anvil carriage 874 and as aresult translates rotational movement into linear movement of the anvilcarriage 874 to provide for linear actuation.

As shown the same linear guide and slide shaft 866 may be used forguiding linear movement of both the sonotrode carriage 878 and the anvilcarriage 874. This maintains alignment between the sonotrode 880 and theanvil 876, which is useful if aligned tooling between components isneeded.

In an embodiment, ultrasonic projection tooling is carried only by theanvil 876, and the sonotrode plate 882 may comprise a flat cooperatingsurface that is free of sonic tooling projections. The flat surface ofthe sonotrode plate 882 faces the projection tooling of the anvil 876.

For example, anvil 876 comprises anvil projection tooling 884 that maycomprise separate anvil tool elements 886, each of which in thisinstance has a welding projection rib 888 that projects outwardly fromrecessed flat surface of the anvil 876 toward the sonotrode plate 882.Welding projection ribs 888 are aligned coincident and in overlappingrelation with opposed side edges 813 of the filter media sheet 810. As aconsequence, when the sonotrode 880 and the anvil 876 are broughttogether with the filter media sheet 810 pinched therebetween and highfrequency energy applied by high frequency sonic emitters 881, weldingof the filter media sheet 812 occurs at the weld locations on opposedsides of the sheet. This welds adjacent pleat panels 870, 872 togetherto form the pocket pleat segments 824. Pocket pleat segmentscollectively are collected and constructed into the pocket pleatedfilter media pack.

To accommodate width sizes of regular rectangular cuboid shaped filtermedia packs or to change the dimension during media pack formation ofirregular shaped packs of other than rectangular cuboid, the separateanvil tool elements 886 can be rearranged upon the anvil carriage 874.For example, anvil tool elements 886 are removable and can be removedand replaced with different tools if desired. In an embodiment, anX-axis linear slide assembly such as linear rail 890 is provided thatcarries corresponding linear slides such as dovetails of each of theanvil tool elements 886. In this fashion, the anvil tool elements 886can be independently moved apart or together along rail 890 to differentpositions in the X-axis 803.

Along the rail 890, each tool element 886 may be stopped such as bybeing fastened by set fasteners in a desired place. Alternatively, alinear servo drive or drives may be used to position the anvil toolelements 886 in fixed positions, such as with a linear servo drives. Forexample, servo motors can be mounted on the rail 890, one for each toolelement 886, each servo motor can rotate a screw that engages a threadformed in the dovetail of its designated anvil tool element 886. Thisprovides various fixed position possibilities for regular shaped packs.This also provides infinite and dynamic positioning (e.g. changing toolposition between consecutive pocket pleat segments) of the anvil toolelements 886, which can be used to form variable width pocket pleats andresult in irregular pleated filter media pack constructions such as inFIGS. 47, 48 and 57 as examples. It is understood in FIGS. 47, 48 and57, when using the present apparatus 850, that opposed side edges ofadjacent pleat panels of packs 418 and 350 are welded along sealed seamsalong opposed edges 813 of the filter media sheet to form pleat pockets,such that flow between flow faces 354 (FIG. 47) cannot pass unfilteredthrough any of the surrounding sides without passing through the filtermedia. Trimming of narrower pleat panels may be conducted by knifeprojection 838 of the tool shown in FIG. 116, or precut by knife 834,which can be drive on a gantry in X-axis 803 (and if desired Z-axis 801)by linear drives such as servo motors or stepper motors.

At the same time, no adjustment of the anvil tool elements 886 may bedone and instead anvil tool elements 886 may be fixed along the X-axis803 to maintain the parallel welding projection ribs 888 at a fixedspacing corresponding to the desired width of the pleated filter mediapack. Such fixed positioning of anvil tool elements 886 can be used toform the rectangular pleat pack 16 with opposed edges 78, 80 such shownin FIG. 43 with form welded seams formed between adjacent pleat panelsto form pock pleats.

In addition to providing optional movement of the anvil 876 (e.g. suchas anvil tool elements 886) in the X-axis 803, movement in the verticalY-axis 802 can be done for purpose of moving the location of the anviltool elements 886 and their welding locations. Additionally oralternatively, movement in the vertical Y-axis 802 can be accomplishedto operate the anvil 876 as a pick member that can hold the filter mediasheet to facilitate filter media sheet advancement when the anvilassembly is drive forward in the Z-axis 801.

In an embodiment and with reference to FIGS. 105, 114, and 115, Y-axis802 movement is accomplished with a further linear actuator such as apneumatic cylinder 892 provided upon the anvil carriage 874. Tofacilitate Y-axis movement of the anvil 876, the carriage 874 canseparated into a support member 875 and a carried member 877, both ofwhich may be plates. The carried member 877 may be mounted for linearmovement to the support member 875 by way of a linear slide assemblyprovided by linear rails 894 and linear slides 896 fastened to thesupport member 875 and the carried member 877, respectively, to affordrelative linear sliding movement between the support member 875 and thecarried member 877. The a pneumatic cylinder 892 has one end acting uponsupport member 875 and the other end acting upon the carried member 877,and is aligned in the Y-axis 802 to linearly actuate the carried member877 and therefore the anvil 876 vertically along the Y-axis 802.

This may be used to pick and advance the filter media sheet 812 asdescribed above and also shown in reference to FIGS. 114 and 115. Themedia support such as the table 864 in this instance supports the filtermedia sheet with the anvil carriage 874 and anvil 876 above. By way ofthe rail 894, the linear slides 896 and the pneumatic cylinder 892, theanvil 876 (or a portion of the anvil carriage such as carried member877) can be moved upward to release the filter media sheet and downwardto pinch the filter media sheet 812. For example, the anvil 876 has agripper such as an elongated bar 898 that grips and holds the filtermedia sheet 812 down sufficiently such that when the anvil 876 is drivenforward in the Z-axis 801, the anvil 876 pushes the leading portion ofthe filter media sheet and pulls the trailing portion of the filtermedia sheet, thereby acting as an intermittent conveyor mechanism. Thisalso facilitates the collapsing and the folding of the pleat panels 870,872 as between the anvil 876 and the sonotrode 880.

Turning now to FIG. 117 and FIG. 118, alternative end face embodimentsof anvils are shown to show alternative tool configurations that may beused. Anvil 900 shown in FIG. 117 has removable tool elements, one toolelement 901 that provides a linear welding rib projection and the othertool element 902 that provides a non-linear welding rib projection witha linear segment and a curved segment for welding a curved recess cutoutregion in the inlet face or outlet face at the corner.

It is also noted that the X-axis movement need not be parallel with thecreases 810 but can be transverse, as shown schematically in thealternative embodiment of an anvil 905 in FIG. 118. Anvil 905 isprovided with a tool element 906, with a curved rib projection forwelding curved seams in the inlet face or outlet face. The tool element906 may be carried on a linear slide assembly 907 and driven linearly byservo motor 908 to dynamically adjust position during operation ondifferent pairs of pleat panels. This can be used for example to weldseams of irregular shapes and dynamic shapes such as shown in the pack400 of FIG. 56.

While focus has been placed upon ultrasonic, other forms of welders maybe employed to achieve thermal bonding. In theory, ultrasonics isthermal bonding by means of exciting the molecules through highfrequency vibration to the point they melt. One other method of thermalbonding would be to press the media between an anvil and a heated plate.In addition “hot wedge welding” uses a concentrated heated air stream tomelt areas of a medium. In all instances including ultrasonic weldingand other types of welding, an anvil is provided along with a weld toolthat are operably coupled with a thermal energy device (e.g. ultrasonicemitter, heating element, or heated air stream element) to providethermal energy that facilitate the welding of weld locations such aswelded pocket seams.

All references, including publications, patent applications, and patentscited herein are hereby incorporated by reference to the same extent asif each reference were individually and specifically indicated to beincorporated by reference and were set forth in its entirety herein.

The use of the terms “a” and “an” and “the” and similar referents in thecontext of describing the invention (especially in the context of thefollowing claims) is to be construed to cover both the singular and theplural, unless otherwise indicated herein or clearly contradicted bycontext. The terms “comprising,” “having,” “including,” and “containing”are to be construed as open-ended terms (i.e., meaning “including, butnot limited to,”) unless otherwise noted. Recitation of ranges of valuesherein are merely intended to serve as a shorthand method of referringindividually to each separate value falling within the range, unlessotherwise indicated herein, and each separate value is incorporated intothe specification as if it were individually recited herein. All methodsdescribed herein can be performed in any suitable order unless otherwiseindicated herein or otherwise clearly contradicted by context. The useof any and all examples, or exemplary language (e.g., “such as”)provided herein, is intended merely to better illuminate the inventionand does not pose a limitation on the scope of the invention unlessotherwise claimed. No language in the specification should be construedas indicating any non-claimed element as essential to the practice ofthe invention.

Preferred embodiments of this invention are described herein, includingthe best mode known to the inventors for carrying out the invention.Variations of those preferred embodiments may become apparent to thoseof ordinary skill in the art upon reading the foregoing description. Theinventors expect skilled artisans to employ such variations asappropriate, and the inventors intend for the invention to be practicedotherwise than as specifically described herein. Accordingly, thisinvention includes all modifications and equivalents of the subjectmatter recited in the claims appended hereto as permitted by applicablelaw. Moreover, any combination of the above-described elements in allpossible variations thereof is encompassed by the invention unlessotherwise indicated herein or otherwise clearly contradicted by context.

What is claimed is:
 1. A method of forming a pleated filter media packwith a filter media sheet, comprising: pleating the filter media sheetto provide a plurality of pleat panels; and welding a plurality of seamsinto a plurality of adjacent pairs of the pleat panels to form aplurality of pocket pleats.
 2. The method of claim 1, furthercomprising: advancing the filter media sheet along a travel path; andsaid pleating comprising creasing the filter media sheet at spacedintervals in order to form the pleat panels with a plurality of pleattips in the pleated filter media pack by extending the creasing in adirection that extends perpendicularly to the travel path.
 3. The methodof claim 1, further comprising after the pleating and welding,overlaying the pocket pleats upon each other to form the pleated filtermedia pack.
 4. The method of claim 1, wherein the pleated filter mediapack comprises a plurality of upstream pleat tips at an upstream faceand a plurality of downstream pleat tips at a downstream face with thepleat panels extending between the upstream pleat tips and thedownstream pleat tips, each of the pleat panels extending transverselybetween first and second opposed side edges of the pleat panels, whereinsaid welding integrally bonds the first and second opposed side edges atspaced apart locations.
 5. The method of claim 4, further comprisingbonding together the adjacent pleat panels at locations between thefirst and second opposed side edges.
 6. The method of claim 4, whereinsaid welding is conducted on at least one of the upstream pleat tips andthe downstream pleat tips at spaced apart locations along at least oneof the upstream pleat tips and the downstream pleat tips.
 7. The methodof claim 1, wherein the filter media sheet comprises at least 10%polymer fibers by weight to facilitate welding.
 8. The method of claim7, wherein the polymer fibers comprise at least one of a polypropyleneand polyester.
 9. The method of claim 1, further comprising welding witha linearly reciprocating press comprising an anvil and a weld tool, andsupplying thermal energy between the anvil and the weld tool from athermal energy device to facilitate the welding.
 10. The method of claim1, wherein said welding comprises ultrasonically welding with anultrasonic press that forms the pocket pleats therebetween, theultrasonic press comprising an anvil and a sonotrode, with a ribprojection being provided along at least one of the anvil and thesonotrode.
 11. The method of claim 10, wherein the rib projection isprovided on the anvil and projects toward the sonotrode.
 12. The methodof claim 10, wherein the rib projection is provided by a removable toolarranged on a plate of at least one of the anvil and the sonotrode, andfurther comprising: removing the removable tool and rearranging theremovable tool or replacing the removable tool with a second removabletool, and using the rearranged removable tool or the second removabletool for forming different configurations of the filter media pack. 13.The method of claim 10, further comprising linearly reciprocating theanvil and the sonotrode relative to each other together and apart toultrasonically weld the seams.
 14. The method of claim 13, furthercomprising: carrying the anvil on a first carriage mounted on a firstlinear slide; carrying the sonotrode on a second carriage mounted on asecond linear slide; and linearly sliding each of the anvil andsonotrode independently, together and apart along a Z axis, tofacilitate the welding of the seams and releasing of the pocket pleatsto allow overlaying of the pocket pleats upon each other to form thepleated filter media pack.
 15. The method of claim 13, wherein thelinearly reciprocating is in a Z-axis, further comprising moving alocation of the rib projection along at least one axis perpendicular tothe Z axis during formation of the pleated filter media pack to form thepleated filter media pack in an irregular shape of other than arectangular cuboid.
 16. The method of claim 10, wherein the ribprojection comprises first and second parallel linear projectionelements in spaced apart relation; and engaging the first and secondopposed side edges of the pocket pleats with the first and secondparallel linear projection elements.
 17. The method of claim 16, furthercomprising a linear slide assembly on which the first and secondparallel linear projection elements are mounted, and further comprising:adjusting a spacing between the first and second parallel linearprojection elements by moving at least one of the first and secondlinear projections along the linear slide assembly during the formationof the pleated filter media pack to form the pleated filter media packin an irregular shape of other than a rectangular cuboid.
 18. The methodof claim 10, further comprising a knife projection provided along atleast one of the anvil and the sonotrode, the knife projection beingthinner than the rib projection; and cutting through the adjacent pairsof pleat panels with the knife projection.
 19. The method of claim 18,further comprising: wherein the knife projection is proximate at least aportion of the rib projection, wherein the knife projection cuts atleast one seam that is ultrasonically welded simultaneously by the ribprojection.
 20. The method of claim 1, further comprising:intermittently and successively advancing and stopping the filter mediasheet along a travel path, wherein while the filter media sheet isstopped at least one of embossing and creasing is conducted and whereinwhile the filter media sheet is advancing the filter media sheet aleading portion thereof is being folded along a crease.
 21. A method offorming a pleated filter media pack with a filter media sheet,comprising: pleating the filter media sheet to provide a plurality ofpleat panels; ultrasonically cutting a plurality of seam edges into aplurality of adjacent pairs of the pleat panels; and bonding and sealingthe adjacent pairs of the pleat panels along the seam edges sufficientlyto prevent unfiltered fluid from passing through the seam edges in thepleated filter media pack.
 22. The method of claim 21, furthercomprising: advancing the filter media sheet along a travel path; saidpleating comprising creasing the filter media sheet at a plurality ofspaced intervals in order to form the pleat panels to provide aplurality of pleat tips in the pleated filter media pack by extendingthe creasing in a direction that extends perpendicularly to the travelpath; and wherein said ultrasonically cutting cuts the seam edges in anextension extending transversely relative to the travel path.
 23. Themethod of claim 21, further comprising: forming a cutout region in thepleated filter media pack with the ultrasonically cut seam edges to formthe filter media pack in an irregular shape of other than a rectangularcuboid.
 24. The method of claim 21, wherein the pleated filter mediapack comprises a plurality of upstream pleat tips at an upstream faceand a plurality of downstream pleat tips at a downstream face with thepleat panels extending between the upstream pleat tips and thedownstream pleat tips, each of the pleat panels extending transverselybetween first and second opposed side edges, and further comprising:ultrasonically welding a plurality of integral bonds along the first andsecond opposed side edges to form a plurality of pocket pleats.
 25. Themethod of claim 21, wherein the pleated filter media pack comprises aplurality of upstream pleat tips at an upstream face and a plurality ofdownstream pleat tips at a downstream face with the pleat panelsextending between the upstream pleat tips and the downstream pleat tips,each of the pleat panels extending transversely between first and secondopposed side edges of the pleat panels, and further comprising:ultrasonically welding the adjacent pair of the pleat panels together atlocations between the first and second opposed side edges.
 26. Themethod of claim 21, wherein an ultrasonic press comprises an anvil and asonotrode, with a knife projection and a rib projection being providedbetween the anvil and the sonotrode to facilitate said ultrasonicallycutting of the seam edges.
 27. The method of claim 26, wherein the knifeprojection and correspondingly the seam edges are curved or non-linear.28. The method of claim 26, wherein the knife projection is provided bya removable tool arranged on a support member of at least one of theanvil and the sonotrode; and further comprising removing the removabletool and rearranging the removable tool or replacing the removable toolwith a second removable tool, and using the rearranged removable tool orthe second removable tool to form a different configuration of thefilter media pack.
 29. The method of claim 26, further comprisinglinearly reciprocating the anvil and the sonotrode together and apart toultrasonically cut the seam edges.
 30. The method of claim 26, furthercomprising: carrying the anvil on a first carriage mounted on a firstlinear slide; carrying the sonotrode on a second carriage mounted on asecond linear slide; linearly sliding each of the anvil and sonotrodetogether and apart along a Z axis to facilitate the ultrasonicallycutting of the seam edges.
 31. The method of claim 30, furthercomprising moving a location of the knife projection along at least oneaxis perpendicular to the Z-axis during the formation of the pleatedfilter media pack to form the pleated filter media pack in an irregularshape of other than a rectangular cuboid.
 32. The method of claim 26,further comprising a rib projection provided adjacent the knifeprojection; the knife projection being thinner than the rib projectionand proximate thereto, and furthering comprising: ultrasonically cuttingthe seam edges while simultaneously ultrasonically welding the cut seamedges to form pocket pleats.
 33. The method of claim 21, furthercomprising: intermittently and successively advancing and stopping thefilter media sheet along a travel path, wherein while the filter mediasheet is stopped at least one of embossing and creasing is conducted andwherein while the filter media sheet is advancing the filter media sheeta leading portion thereof is being folded along a crease.
 34. A methodof forming a pleated filter media pack with a filter media sheet,comprising: creasing the filter media sheet to provide a plurality ofpleat panels; arranging a crease created by the creasing between a weldtool and an anvil; and assembling an adjacent pair of the pleat panelsby reciprocating the weld tool and the anvil together and apart relativeto each other; and optionally, welding the adjacent pair of the pleatpanels at a weld location while the weld tool and anvil are together.35. The method of claim 34, wherein the reciprocating comprisesfacilitating relative linear reciprocating movement between the anviland the weld tool along a linear slide assembly.
 36. The method of claim35, further comprising driving at least one of the weld tool and theanvil with a servomotor or a stepper motor.
 37. The method of claim 36,wherein a first servomotor linearly reciprocates the anvil and a secondservomotor linearly reciprocates the weld tool.
 38. The method of claim34, wherein the weld tool is a sonotrode and further comprising emittinga vibration frequency of at least 15,000 hertz along the sonotrode toweld the pleat panels.
 39. The method of claim 34, wherein one of theanvil and the weld tool is part of a pick member and the other one ofthe anvil and the weld tool is part of a stop member, wherein saidassembling comprises: holding the filter media sheet with the pickmember and advancing the filter media sheet during the holding towardthe stop member by pulling a trailing portion of the filter media sheetwith the pick member and pushing a leading portion of the filter mediasheet with the pick member, wherein the leading portion comprising theadjacent pair of the pleat panels; folding the leading portion of thefilter media sheet along the crease by driving the pick member and thestop member together.
 40. The method of claim 39, further comprisingreleasing the assembled adjacent pair of the pleat panels from betweenthe weld tool and the anvil and overlaying the assembled adjacent pairof the pleat panels onto a partly formed portion of the pleated filtermedia pack to form a pleated segment of the pleated filter media pack.41. The method of claim 40, wherein said releasing comprises driving thestop member away from the pick member to open a region for the assembledadjacent pair of the pleat panels and gravitationally dropping theassembled adjacent pair of the pleat panels through the region onto thepartly formed portion of the pleated filter media pack.
 42. The methodof claim 39, wherein the anvil is part of the pick member, and furthercomprising: driving the anvil and the pick member up to release thefilter media sheet in a release state and driving the anvil and the pickmember down to hold the filter media sheet in a hold state; andadvancing the pick member in the hold state, and after advancing thepick member in the hold state, releasing the filter media sheet toachieve the release state and retracting the pick member to a startposition.
 43. The method of claim 34, further comprising pushing thecrease vertically upward during the assembling to facilitate folding ofthe pleat panels.
 44. The method of claim 35, further comprising:cutting first and second edges into the adjacent pair of the pleatpanels; wherein the first and second edges are extending obliquelyrelative to the crease for creating an irregular shape to the pleatedfilter media pack; and welding the first and second edges to form awelded seam.
 45. The method of claim 44, wherein the cutting and thewelding are conducted simultaneously while the weld tool and anvil aretogether during said welding of the adjacent pair of the pleat panels atthe weld location.
 46. The method of claim 44, wherein the cutting isconducted separately after the creasing but before the assembling. 47.The method of claim 44, wherein the cutting is conducted separatelybefore the creasing.
 48. The method of claim 34, further comprising:welding a plurality of seams into the adjacent pairs of the pleat panelsto form a plurality of pocket pleats, wherein the pleated filter mediapack comprises a plurality of upstream pleat tips at an upstream faceand a plurality of downstream pleat tips at a downstream face with thepleat panels extending between the upstream pleat tips and thedownstream pleat tips, each of the pleat panels extending transverselybetween first and second opposed side edges of the pleat panels; andwherein said welding integrally bonds the first and second opposed sideedges in spaced apart weld locations.
 49. The method of claim 48,wherein the filter media sheet comprises at least 10% polymer fibers byweight to facilitate welding, and wherein the polymer fibers comprise atleast one of a polypropylene and polyester.
 50. The method of claim 48,wherein an ultrasonic press is used to ultrasonically weld the pluralityof pocket pleats; wherein the ultrasonic press comprises the anvil andwith the weld tool being a sonotrode, with a rib projection beingprovided along at least one of the anvil and the sonotrode.
 51. Themethod of claim 50, wherein the rib projection is provided by aremovable tool arranged on a support member of at least one the anviland the sonotrode, and further comprising: rearranging the removabletool or replacing the removable tool with a second removable tool, andusing the rearranged removable tool or the second removable tool forforming different configurations of the filter media pack.
 52. Themethod of claim 50, further comprising: carrying the anvil on an anvilcarriage mounted on a first linear slide; carrying the sonotrode on asonotrode carriage mounted on a second linear slide; linearly slidingeach of the anvil and sonotrode together and apart independently along aZ-axis via the anvil carriage and the sonotrode carriage, respectively,to facilitate the welding and releasing of the pocket pleats in order toallow overlaying of the pocket pleats upon each other to form thepleated filter media pack.
 53. The method of claim 50, wherein the anviland sonotrode are reciprocated relative to each other along a Z-axis;and moving a location of the rib projection along at least one axisperpendicular to the Z axis during formation of the pleated filter mediapack to form the pleated filter media pack in an irregular shape ofother than a rectangular cuboid.
 54. The method of claim 50, furthercomprising a linear slide assembly on which first and second parallellinear projections are mounted, and further comprising: adjusting aspacing between the first and second parallel linear projections bymoving at least one of the first and second parallel linear projectionsalong the linear slide assembly during the formation of the pleatedfilter media pack to form the filter media pack in an irregular shape ofother than a rectangular cuboid.